TWIN Motorcycles

17-9-2016 Buell Ulysses leaking exhaust gasket / mouting good exhaust. Buell XB crash repair

Source: TWIN Motorcycles

 

17-9-2016 Buell Ulysses leaking exhaust gasket / mouting good exhaust. Buell XB crash repair

the front header on this Uly is leaking

as the nuts had rattled loose

all becaus there is no front exhaust mount, so the exhaust basicly hangs on the header… will fix this

ncie Uly

start striping topside

top tie rod off and electrics disconneted

removing the old iron

simons car exhaust ?

front stud came out the head, lucky non broke this time

engine supported, and removing the front bolt

and dropping the engine to remove the header

front header retaining clip for the flange, this broken clip is way tightening the nuts did not help with the leak

has been ratteling for some time

intake manifold out to, as the intake seals where leaking , allen bolts right side

front sprakplug is also gone , will replace this

spark plugs looks like they have been in a very long time… will replace these

running lean

throttle body out , and let it cool for a while

first new stud in and clean out the gasket aria with a scrape

double up 2 exhaust nuts to turn the stud in

note the height it needs to be turned in, as this model has the tick flanges the studs need to stick out more

new retaining clips on the exhaust to hold the flange

and headet back on … fideling witht he nuts to start theme ( rear )

throttle bodie cleaned and new gaskets in tighen it evenly

sparkplugs in the easy way 🙂

and new cable on

checking the rear cable… the lock clip was broken,

lock clip use from the rubbed down front cable , make sure you hear these clip on so there secure

engine back up and front bolt cleaned and put some neverseas on

notished the right front seal was also leaking … will fix this right away

protecting the top cap from scars with some isolation tape

new seals on again isolation tape on the sharp edges off the front leg to protect the new seals , and fork back in place

the alu front exhaust mount bushings in the case

and nice TQ hammer exhaust ready to be put on

rear straps loosly mounted.. front the front secure and with out tension before tightening the rear

everything tightenend and tapped the tension out the front pipe connection , and the clamp can be put in

decal on… nice even with out front spoiler

conencting the top side.. ziptie the tps wire to the fuel rail so the wire ends going in the sensor will not move to much

cut off and removed, old exhaust valve actuating cable , and she is ready to go

bad mishap… very unlucky new owner just bought the bike… need to get it going for now

tail piece is completely broken off

stripping the tail first.. battery out

seat lock bracket 😦 broken off the seat

wire loom and fuse box loose and out

removing all the screws

bought side rails broke

lucky the frame tabs are still intact

fuse box/ seat lock bracket bend… easy to straigten

as the bike did fal on the swing arm.. it has moved in , loosening the pinch bolt

and loosening the axle a little the swing arm pops back out

now the side rail top mount bolt broe off

bought sides

drilling a pilot hole left twist dril , left came out east

right side neede to tap a old tq bit on to unscrew

 

 

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=958

29-9-2016 – Buell 1125R stalling issues, Buell X1 fuel pump and injectors, Buell XB electrical problems

Buell 1125R stalling issues, Buell X1 fuel pump and injectors, Buell XB electrical problems

Source: TWIN Motorcycles

 

29-9-2016 – Buell 1125R stalling issues, Buell X1 fuel pump and injectors, Buell XB electrical problems

1125 R in from Belgium, stalling when hot

as the customer also asked to check the valveplay, i need the strip the bike

vacuum hose is a little to low, will check and zip tie this to the port

cruddy… allweaterh bike

this is a HDI model ( French model ) normaly with 105 HP… this one has been unfreched and the trottle stop is been removed ( the limitation is the throttle opening )

this is a HDI model ( French model ) normaly with 105 HP… this one has been unfreched and the trottle stop is been removed ( the limitation is the throttle opening )

but now means there is no max opening stop.. so i can turn the rear throttle over 90 deg

checking cooling fan’s as the customer was not sure they work… the workings surpriced me to , left fan is sucking

and looks like the right fan is blowing ? ( but i think the airflow off the left fan turns this fan to ) this is low speed 1e stage cooling

engine is getting hot ? normaly this would not happen idle , and battery charging is very low

checked the stator leads, all 18 V ac, stator is ok

but the wire harness modifocation is still mounted, means very low charging below 5000 rpm

coolling fan “high” Speed, contact off and hot… bought fans suck now

stator directly to the regualtor to test

charging much better

still the engine stalls after heat soak… fuel pressure ? error light douse not burn

sensor disconnect

sensor react in the ecm

ok ground issue ?

a little much resistance to ground, when i rotate the engine i will check the ground point on the cylinder head

but no sensor will fix this… no fuel pressure when the bike has tun for a while ( heat soaking the right side off the frame ) i bet the fuel pump is broken

ok 1125 to cool off … X1 problems, intake seals and fuel pump pressure , air box cover off

and draining the fuel tank by using the test option

while draining i take off the inner airbox

and the brackets

throttle cables off to remove the throttle bodie

old spark plug works as fuel line plug so the filter douse not drain

200 Lbs Gorilla thight

will leave it marks on the allen heads

and throttle bodie off

i will clean and test the injectors now to

mnnn i will clean these , to see if they will pick up some

on with the pressure regulator , you need to remove the fuel cap ring for this

bigger hole to get the pump out

nut and fitting loose

and uyou can take the pump out

old regulator and srubby rings

the seals on teh tank it self are also bad

new regulator on ( o-rings are included )

and new outer rings on

hand deep in the fuel tank and put the wire through

little hylomar to seal the cap again

after cleaning and high rpm testing bought injectors started to perform better…

new o-rings on and injectors back in place

line up the manifold with the front bracket

and 577 loctite on the breather plugs

fuel pump back on

after bleeded… pressure is good and stays like this

only after a 15 minutes the fuel pressure drops, i woudl say good 🙂

orignal airbox back on… manmanman what a system :-X

and test ride 🙂

2e test with the 1125, after cooling it got fuel pressure again

stock ecm in just to check the ecm was not still the hdi firmware

agian charging good

and temperature stays around the 80 deg.. idle as it should

but after 15 minutes idle , the fuel pressure drops

back to zero and the engine stalls… was not really hot yet, but fuel tank is heat soaking , will contact the customer and advice to replace the fuel pomp

XB9SX from Germany, electical gremlins

first thought… cables but also notished the battery try is loose

afv was at 70 ? and bike would not run… set back to 100 and after some time ego correction was going to 128 ? leaking seals ? to little fuel pressure ?

bike has been tinkered with , as the stack in not on fully

new tps sensor was fitted.. shame the did not ziptie it to the fuel rail so the wire connections will have a longer life

fuel pressure test… no problem here… all good

cable harness t the ecm douse have some issues

on more than one stop

mnn

other start

best to take this out and reisolate the dammage

and retaped the wires .. and routing this so it can not rub anymore

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=957

15-9-2016 Buell XB front fork seal , Buell X1 trouble shooting , Buell M2 rebuild, Buell 1125R leaking.

15-9-2016 Buell XB front fork seal , Buell X1 trouble shooting , Buell M2 rebuild, Buell 1125R leaking.

Source: TWIN Motorcycles

 

15-9-2016 Buell XB front fork seal , Buell X1 trouble shooting , Buell M2 rebuild, Buell 1125R leaking.

Xb12 X font fork seals are leaking , usefull protection on the top cap to remove it

in the spring compressor, works so much better than to turn off the preload adjsuter

dust seal and retaining clip off

and pull the legs apart like a slide hammer , remove the guide seals and check the condition

little craches on the leg, will clean it off a little with fine scotchbrite in a cross pattern

and some pitting on the leg, will try it ones… if the seal fails again, i would recommand to replace the front leg

new dust seal, put the retaining ring on theme so this will not scratch the leg any further

some isolation tape on the sharp edges off the leg and slide the seals over

guide bushings back on, hammer the oil seal home

retainer back in , and oil seal on

bleed the dampening by pushing the rod up and down intill you feel al air is gone , and fill to level

leg back in and assembly further

axle to TQ

please no grease on the caliper bolts

seen these come loose to many times loctite please

fender back on

fender back on

and rebuilding the top side

checking iff the loose front header has disturbed the afv settings… looks like it as the idle is way to low

ahhh ilde is low because it is set way to low… tps reset and idle back to 1000 rpm.. rides better

X1 after hish speed ride the big will not run good anymore…AFV was to 150

supect the fuel pomp / regulator is leaking so it gives to little fuel , adaptor for the pressure meter mounted to the schreader test adaptor on the fuel cell

priming pressure is ok

but the pressure drops off very quick.. and i hear it bleed off in the fuel tank.. i supect the o-rings on the pressure regulator are leaking

and the intake seals are shot… will contact the customer

nice bike and respectable km

m2 rebuild. fitting back the spacer for the shock canister

wires ignition sensor back on the connector

routing the wires and front pully back on

there is always a position the lock plate will fit

wheel in line and belt to tension

i cannot really adjust the primairy chain, as 1 cylinder is still off ( stil waiting on it 😦 ) but this wil do for now

oil pressure sensor bak con

and routing and zip tie the wires neathly

oil cooler on… need to remove the top shock mount bolt for this..

you really need to get the weight off the shock for this… the mount will turn on you

ol cooler on

for a home made mod… not bad

i felt the front brake lever and it is slow in return… a sign there is some thing not really ok

and booth rubber looks like it has it best days some years ago

take off the mastercylinder… the piston looks like crap

with a overhaul kit it will work perfect again , the bore was not corroded yet

the new oneway rubber in , followed by the new piston, put a little brake seal grease on these

little silicone grease in the booth, so if there is watter penitration there is a grease barrier

snapy action now on the lever

and bleeding the system , dot 5 for these classic buells

this bike was brought in by the road assistance.heavy oil leaking clutch side, customer called ” thought the engine had explode ”

not the engine… clutch has been leaking a long time to the inside… keep filling the reservoir… when the space between the cover and the vacuum membrame is filled , the oil will come out anyway it can, when the clutch is pulled

cover off… yes indeed leaking hard..

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=956

14-9-2016 Buell M2 rebuild, Buell XB12Scg troubles, Buell XB Hammer time, Buell XB fixing broken studs.

14-9-2016 Buell M2 rebuild, Buell XB12Scg troubles, Buell XB Hammer time, Buell XB fixing broken studs.

Source: TWIN Motorcycles

 

14-9-2016 Buell M2 rebuild, Buell XB12Scg troubles, Buell XB Hammer time, Buell XB fixing broken studs.

M2 oil tank fittings back in , i use a little hydrolic loctite here, to help against sweating

the jam nut on the fitting tightened with the fitting correctly in place

oil tank back in, to give my self some more space i remove the rear wheel as we need to replace the tyre anyway … this one is a little to attached to the bike as i need to hammer it out

yep… would look like that

now first rear tierod and ground back on, and oil tank lower bolts

cleaned up the axle a little 🙂 and cleaned out the spacers , and with some silicone grease back in

nice XB from Germany..

needed a little upgrade tuning for the old style race exhaust

back to the M2.return fitting back in the oil tank and running the lines down

header wrap.. customer wanted the heat shield back on… looks good in the style off the bike

primairy side, oil seal in , handy if you have a stamp for these

adjusting the shifter

and primairy drive back on , red lock tite on the nuts !!

XB12SS in need off some sound… we have that… and will ad some TQ along the way 😉

first the chin spoiler off

exhaust clamp loose

and straps off

no longer used… i will remove this completely

TQ hammer… ready to go on

rear straps in place and front mount on

nice …

removing the exhaust cable on the top side and placing a K&N filter

and after the fuel mapping put in… test ride 🙂 nice

M2 clutch pulling plate back in

primary cover back on , blue loctite and tq to 14 Nm

gearbox oil back in

shifter mechanimse back on.. use some loctite on the bolt

M2 position shifter pointing to the screw on the cover

front tie rod bolts and clutch cable bracket on

checking the oil pressure valve

as a oil cooler adaptor is mounted, i use red loctite on the filter adaptor

oil filter adaptor on

and oil filter pick up threads on

uly with a stud problem

stipping the top side as we know what needs to be done… leaving the fuel line and throttle cables on, only the top tierod bolt off and the clutch cable out the lever

mnnn.. strange how you start to recognise screws.. this is a manifolt screw 😉

chin spoiler off, even with stock exhaust these crack over time

m6 in 1/4-20 yup… i see it more 😦

clutch cable out

and the start off the problem… missing front mount

clearly this exhaust is put on when the bike was sold… straps the “lazy” way

and a XB9 exhaust was used … on a uly the straid outlet will hit the side stand

xb9 stock exhaust… no valve , must be one off the early ones

clutch cable looks like it is replace some time ago… now is rubbing against the oil lines , they act like a file

should be a cable bracket on the cable, to keep it off the oil lines

anyway… the broke stud…

needed some penitrating oil to get the one left on out

and it came out stud and all

engine supported, to remove the front engine mount

it douse not have to go down allot, just enought to get to the header nuts

o2 sensor disconnected and header can be take off

for the drilling tool to use i need to remove the post gasket

and mount a new stud, using 2 off the nuts jammed to each other to screw the stud in

i made some long dril bits to help with drilling, not needed for this position , but very handy

drilled the core out the stud, and retapping to 5/16 unc

and new stud in

and new gasket always a pain to put these in

header back on the ports and fingering the nuts on the rear studs

engine back up and front mount bolt tightened

w-brace back on

new bushings for the front exhaust hanger

and new saddle brace to hold the strap

i will mount the rear straps the “nice” way

thightening the front strap… not to loose , not to tight … as the break very easy

i will replace the leaking seal to , with the bike still supported on the rear stand , and center lift

i can take out the leg and leave the rest on

yep… would look like that

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=955

9-9-2016 Buell XB rattle belly pan, Buell Ulysses throttle shaft, Buell Ulysses exhaust problem

9-9-2016 Buell XB rattle belly pan, Buell Ulysses throttle shaft, Buell Ulysses exhaust problem

Source: TWIN Motorcycles

9-9-2016 Buell XB rattle belly pan, Buell Ulysses throttle shaft, Buell Ulysses exhaust problem

belly pan was rattleling a little as it is a carbon big one, noise will be enhanged — bij Twin Motorcycles Buell Support forever.

checking the tighness off the straps on the exhaust to see if it has been setting — bij Twin Motorcycles Buell Support forever.

retighten the front clamp after this — bij Twin Motorcycles Buell Support forever.

and loctite on the screws… only 3 holding this one up — bij Twin Motorcycles Buell Support forever.

nice bike 🙂 — bij Twin Motorcycles Buell Support forever.

uly with throttle problem — bij Twin Motorcycles Buell Support forever.

stack is not mounted good… crews are acounted for — bij Twin Motorcycles Buell Support forever.

breather hoses put in in the wrong hole — bij Twin Motorcycles Buell Support forever.

yep throttle shaft broke — bij Twin Motorcycles Buell Support forever.

and vacuum cap not there. — bij Twin Motorcycles Buell Support forever.

so first off the throttle cables — bij Twin Motorcycles Buell Support forever.

airscoop off — bij Twin Motorcycles Buell Support forever.

other side scoop off , oil is dripping from the base gasket — bij Twin Motorcycles Buell Support forever.

and the head gasket is blowing oil to — bij Twin Motorcycles Buell Support forever.

ok first check all the parts off the throttle shaft are still there , clutch cable off — bij Twin Motorcycles Buell Support forever.

and support the engine to remove the front bolt — bij Twin Motorcycles Buell Support forever.

mnnn will clean and lube this — bij Twin Motorcycles Buell Support forever.

throttle bodie off — bij Twin Motorcycles Buell Support forever.

and check the plugs to see if they are damaged — bij Twin Motorcycles Buell Support forever.

wet and dirty from not running good ( broken throttle shaft ) — bij Twin Motorcycles Buell Support forever.

all parts accounted for… ok why is the head gasket blowing oil — bij Twin Motorcycles Buell Support forever.

i could easy give the outer head bolt a turn.. should not go this easy.. a sign the tension is off the studs , could be the basegasket is blown out, — bij Twin Motorcycles Buell Support forever.

checking comperssion , ok… with in margin.. only small leak , more leaking oil — bij Twin Motorcycles Buell Support forever.

rear plug out to check — bij Twin Motorcycles Buell Support forever.

rear has a little more compression, i will take the front off to check — bij Twin Motorcycles Buell Support forever.

exhaust needs to come off ad we need to remove the header — bij Twin Motorcycles Buell Support forever.

craptactic these jardine pipes, been rivited already more than ones.. and the holes have become slots— bij Twin Motorcycles Buell Support forever.

lucky… all 4 come off exhaust nuts — bij Twin Motorcycles Buell Support forever.

o2 sensor wire connector loose — bij Twin Motorcycles Buell Support forever.

and remove the header — bij Twin Motorcycles Buell Support forever.

coil bracket needs to come off — bij Twin Motorcycles Buell Support forever.

rocker box cover off — bij Twin Motorcycles Buell Support forever.

and loosening the rocker box, loosen smal bolts first — bij Twin Motorcycles Buell Support forever.

than the 5/16 ones , little rag on the front as this will leak there — bij Twin Motorcycles Buell Support forever.

bumpstick out — bij Twin Motorcycles Buell Support forever.

and loosening the head bolts — bij Twin Motorcycles Buell Support forever.

oil has been leaking from the base gasket up, looking at the crap on the outer rear head bolt — bijTwin Motorcycles Buell Support forever.

and the left side gasket comes clean off, normaly these gaskets will pull apart when you remove theme , like on the right side — bij Twin Motorcycles Buell Support forever.

bore looks ok , little wear marks , but ok — bij Twin Motorcycles Buell Support forever.

base gasket was gone , and scrapes off easy — bij Twin Motorcycles Buell Support forever.

so little cleaning further… indexing the rings , and ring mounting tool on — bij Twin Motorcycles Buell Support forever.

and the cylinder back on its base — bij Twin Motorcycles Buell Support forever.

fresh head gasket… degreased the surface — bij Twin Motorcycles Buell Support forever.

now first the pushron cover back on — bij Twin Motorcycles Buell Support forever.

new o-rings place int he head, wet finger off oil to protect these during mounting, and press the head over the pushrod covers first , before you locate the positioning dowls in the cylinder — bij Twin Motorcycles Buell Support forever.

hed bolts, lube the threads and the flats to get the correct tension in the studs — bij Twin Motorcycles Buell Support forever.

and tighten the the head bolts step by step — bij Twin Motorcycles Buell Support forever.

bumpstick back in.. with out marking … easy. long ones are exhaust — bij Twin Motorcycles Buell Support forever.

new gasket on, rocker box back on.. position all the bolts to line out the gasket — bij Twin Motorcycles Buell Support forever.

and start slowly tightening first the 4 5/16 bolts keep the box level , and do multiple steps to bleed the lifters if needed.. than the 5 1/4 bolts — bij Twin Motorcycles Buell Support forever.

new gasket on , and outer cover back on — bij Twin Motorcycles Buell Support forever.

coil bracket back on — bij Twin Motorcycles Buell Support forever.

now first the throttle shaft — bij Twin Motorcycles Buell Support forever.

the wire end out , felt ring, nylon spring guide, cam and nut the nylon bearing is still in the throttle body— bij Twin Motorcycles Buell Support forever.

tps sensor off — bij Twin Motorcycles Buell Support forever.

2.5 mm allen some will come out , as there locked , others you need to drill the heads off to recover the butterlfy , this one i could unscrew it — bij Twin Motorcycles Buell Support forever.

and the tps pick up side out — bij Twin Motorcycles Buell Support forever.

little ceramic grease on the idle adjuster — bij Twin Motorcycles Buell Support forever.

new shaft in place , with nylon bushings and felt ring — bij Twin Motorcycles Buell Support forever.

butterfly cleaned and positioned in the shaft slot , put the 2 little screws in with loctite, do not tighten these yet, first put the spring and cam back on, than thighen the butterfly screws — bij Twin Motorcycles Buell Support forever.

checking the orientation off the tps sensor, as we make this replacement throttle shaft for 04-06 and 07 models tps sensor , and put the litte pin in and mount the tps sensor — bij Twin Motorcycles Buell Support forever.

new seals and throttle bodie back on — bij Twin Motorcycles Buell Support forever.

header back on — bij Twin Motorcycles Buell Support forever.

and engine up and tighened the bolt to 66 NM — bijTwin Motorcycles Buell Support forever.

the gearbox breather hose was lying loose , better to keep it off the header pipe using a ziptie — bij Twin Motorcycles Buell Support forever.

W-brace back on, and inner piece off the big airscoop — bij Twin Motorcycles Buell Support forever.

hooking up top side fasten the tps sensor wire to the fuel rail, will keep the sensor in better shape as the wires don’t rubb to much — bij Twin Motorcycles Buell Support forever.

all done — bij Twin Motorcycles Buell Support forever.

resetting tps — bij Twin Motorcycles Buell Support forever.

should be zero tps when closed… after resetting , turn up to about 5,3 to get a idle reading adjust the idle rm when hot to 1000-1050 rpm — bij Twin Motorcycles Buell Support forever.

and she is smooth again very nice — bij Twin Motorcycles Buell Support forever.

rest off the plactics on and test ride 🙂 — bij Twin Motorcycles Buell Support forever.

rattle in Uly… bolt missing… mnn one look, not missing — bij Twin Motorcycles Buell Support forever.

stud broke in the head — bij Twin Motorcycles Buell Support forever.

stud broke in the head — bij Twin Motorcycles Buell Support forever.

all because the ( i asume ) the previeus owner , mounted back the stock exhaust but for got to mount the front mount staps and hanger back on, when he sold the bike — bij Twin Motorcycles Buell Support forever.

and front seal is leaking… will be next week — bij Twin Motorcycles Buell Support forever.

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=954

8-9-2016 Buell firebolt mounting indicators, Buell M2 update engine rebuild

8-9-2016 Buell firebolt mounting indicators, Buell M2 update engine rebuild

Source: TWIN Motorcycles

 

8-9-2016 Buell firebolt mounting indicators, Buell M2 update engine rebuild

Firebolt in , no indicators

to get to the electrics, we need to remove the front fairing , mirror block plates off and the bottum screen bolts out

and removing the indicators to get the fairing off

this one is broken, lets see if it still works, and we replace the stem

power on the feed, tried a new relais first…

with the new relais.. the indictors work again and the broken one douse work aswell

the kellerman indicators come standard with rubber stems

but there are also steel ones… i will mount a set off these

new connections made to the wires

and working…

M2 piston rings orientated and put in the cylinder, for easy connecting to the rod end

double check the pistons are facing the right wa

and the other piston pin lock ring in place, protect the case hole in case the rings slips and falls in

prepeing the heads, valve guides where still ok.. valves needed a little cleaning and grinding , put the valve stem seals on

a dop off oil under the spring washer as the springs will rotated when running

spring spanner on, and put the keys in to lock the collor

check that there in good

and on with the other valve

head on, and tighen hand tight

and tighten to specification

pushrod covers back in

these can be a pain to mount, i put the rubber first in the plate and slide the pushrof tube lightly oiled through

and tighen the base plate

next one

bumpstick back on, with the new tappeds you feel spring tension as these are not filled yet with oil

and rocker box back on, old style bolts… long ones and short one , look for that !

spacer ring back on and i will put a new umbralla valve in for the breather , and mount the top cover

front head mounting bolts… really neverseas… please these break if the loosen… so put these in with loctite

bolts cleaned and red loctite on

bolts tighten noe the front hanger bold back in

and tighten…

shock on

and on his own feet again

removing the oil tank to clean it out… important after a engine bearing failure… i think i will mount this ground to a other spot.. on the wellnut bolt can not be tightened very hard ..

removing the oil hoses , breather

and oil return.. i remove this fitting to pas the tank through the frame , the nut is a jam nut for the fitting

and has a o-ring seal

so tank out

and cleaning

when it rains it pours… i was hoping to finish this one, this week, as it just would not go smooth with this one. crank warped, back, now cylinder, it was packet good, but still it got damaged in the mail, aaahhh… new one was rushed out the the engine shop to bore and hone to size… but with out a cylinder there is not much i can do on this bike 😦

 

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=953

7-9-2019 Visit from Switserland, service and repairs Buell XB, Buell M2 bigbore first startup, Buell m2 2e try engine overhaul.

7-9-2019 Visit from Switserland, service and repairs Buell XB, Buell M2 bigbore first startup, Buell m2 2e try engine overhaul.

Source: TWIN Motorcycles

7-9-2019 Visit from Switserland, service and repairs Buell XB, Buell M2 bigbore first startup, Buell m2 2e try engine overhaul.

early morning arrival from Switzerland, cooling fan is broken (hence rocker cover gasket leaking ) bike running rough between 2500-3000 rpm and big service

heating up the bike, diagnose the intake seals are leaking a little ,

and the cooling fan is broken down by oil leaking fromt he rear rocker box

with a big service, you can combine allot off things… engine rotation, sparkplugs, intake seals rocker cover gaskets … all in one go

not really happy with this breather mod… the wires are rubbing on the tps sensor harness

while the bike is very clean… the signs are visible in the cooling fan ( fuse is also broken )

as we suspected, old orange seals

will replace these with the new black seals… these are harder, and will not leak anymore

engine back up , rear off the bike supported, and rear schok out, to replace the cooling fan… and a little cleaning

smart modification on the M2… keeps the spray from the rear wheel off the oil tank

fuel tank back on

and she is smoking… nice first warm up… running nice

M2 again… crank alined again, now should work better, keep these rings with the bearings as there set to size by set

pulling on the outer bearing

and degreasing the case halfs before putting sealent on

pignon bearing back on prelube , and snap ring in place

cases back to getter i also mount 2 off the 5 gearbox bolts to let the gasket set

now making the bike ready… tail section off

nice modification, the electrics are out the way off wheel spray

fuel tank off… note not really a fuel tank clamp system ( should be retension plates in there )

naked…. rear in the hoist…

case mounted to the swingarm adaptor and front mount on

belt back in place and tightening the rear isolator bolts

5e gear… easy pulling this in with the jims tool

5e gear in place, a little starting lube in the bearings and on the seal lips

the spacer can be cleaned a little as this is hardened steel.. with a little scotchbrite you can clean off the old running marks

seal pressed in , squire o-ring in first

and than the spacer beveld side first

gearbox in

little silicone on the stator plug to help it seal

and stator on

gear shift mechnisme on for now, need to adjust this later

and new woodfuss key in the crank pignon side

new tappeds, hole to the front or rear 😉 this case to the front …

new o-rings on the lifter guide pins

and the lifter guide pin covers back on

timing the cams…

we already checked the oil pump… a little prelube to let it smootch better

loose fitting

with some hydrolic sealent, back in place

new gear cover cam seal

last change before the cover is on… prime the crank to feed the big end bearings ,

cam cover on , nice cut

and tq the cover down

timing cup in place

and pick up set to old settings…will check this when the electrics are on

starter motor on

and oil pressure feed hose to the oil filter housing

feed pressure hose on

cylinders on… don’t forget the base gasket

checking the new piston pins in the rod ends… should move smooth with out play

checking the piston ringgap

these are good to go, as about 98% are with these sets… but alwasy check

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=952

3-9-2016 Buell XB12R lowering, Buell M2 bigbore rebuild

3-9-2016 Buell XB12R lowering, Buell M2 bigbore rebuild

Source: TWIN Motorcycles

3-9-2016 Buell XB12R lowering, Buell M2 bigbore rebuild

very nice XB12R needed some lowering

first the rear, seat off

as we need to remove the rear shock the tail had to come off aswell

wiggling the canister throught the frame

knowing where we are at now

bike supported

with the bike supported, the shock can be loosend

and the shock can be pulled out top side

in the shock press so i can remove the spring retainers

the new lowering ring , the slot needs to be positioned like this so you can still adjust the rebound

and out the press ring on, bump rubber slided back

2 cm drop nice 🙂

tail section back on , the carbon is not as flexible as the OEM plastics and needs a little help to fit nice with the undertray

rear is done

now the front…

front wheel out

and noting the height off the forks now

little protection in the top caps

and the top caps off so we can shorten the preload tubes

tubes cut and debured

mount the bottom nylon ring on the cut off side, so you still have the tool hole in the tube on top

forks to getter and mounting back

wheel back to TQ

after pressing in the suspention a few times, tighen the axle pinch bolts

and a drop in front off 2 cm , and room to give it a little more

M2 belt tensioning

and tq the rear axle

primairy chain tension check

and exhaust back on

the pressure canister for the technoflex ( wilbers ) mounted on the frame tube

and rear fender in place

battery and catch can back… almost ready to start here up 🙂

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=951

2-9-2016 Uly Health check, muller clutch, M2 bigbore rebuild

2-9-2016 Uly Health check, muller clutch, M2 bigbore rebuild

Source: TWIN Motorcycles

2-9-2016 Uly Health check, muller clutch, M2 bigbore rebuild

Uly in for a health check, oil pump gear check

drain plug shows a little very fine metal, not really uncommon with 50000 km — bij Twin Motorcycles Buell Support forever.

to check the oil pomp gear we need to remove the exhaust — bij Twin Motorcycles Buell Support forever.

rear strap douse not want to play nice as the T bolt is slipping in the strap — bij Twin Motorcycles Buell Support forever.

clamping it down i could unscrew the nut , and clean the threads before i mount it again — bij Twin Motorcycles Buell Support forever.

nice time to check the no, 77 plug… looks perfect — bij Twin Motorcycles Buell Support forever.

clearing out the wires in front off the oil lines and oil filter off to get to the out line — bij Twin Motorcycles Buell Support forever.

please use a spanner to hold the fittings… they break to easy , first the press side — bij Twin Motorcycles Buell Support forever.

than return — bij Twin Motorcycles Buell Support forever.

and than the oil feed — bij Twin Motorcycles Buell Support forever.

loosen the feed line clamp a little so you can slide it backwards — bij Twin Motorcycles Buell Support forever.

with the oil lines off, you can remove the 2 allen bolts holding the pump — bij Twin Motorcycles Buell Support forever.

and out she is — bij Twin Motorcycles Buell Support forever.

now with a mirror and light you can check the oilpump gear, — bij Twin Motorcycles Buell Support forever.

little to no wear on it, would be a bad thing if the upgraded oil pump gear showed wear, could indicate a crank warp , this one is good — bij Twin Motorcycles Buell Support forever.

so new gasket on and little loctite on the screws and the pump back in place — bij Twin Motorcycles Buell Support forever.

oil lines back on again, same sequence i did loosen theme — bij Twin Motorcycles Buell Support forever.

hold the fittings when you tighen the lines… so they dont turn or break — bij Twin Motorcycles Buell Support forever.

new oil filter on , — bij Twin Motorcycles Buell Support forever.

and hooking up the conenctors, little dielectric grease to make shure they stay good — bij Twin Motorcycles Buell Support forever.

prepairing for next time the exhaust needs to come off , cleaning and put some neverseas on the threads , the next guy who needs to loosen these will love you for it 🙂 — bij Twin Motorcycles Buell Support forever.

so little inspection top side in the airbox — bij Twin Motorcycles Buell Support forever.

as this tells allot about the piston rings , these are on there way out on this bike, little oil spatters are ok… a puddle not the piston rings are getting worn out — bij Twin Motorcycles Buell Support forever.

04 bike heavy clutch , easy fix — bij Twin Motorcycles Buell Support forever.

trun in the outer cable adjuster… and put some neverseas on the threads — bij Twin Motorcycles Buell Support forever.

clutch inspection cover off and remove the ball and ramp mechanisme — bij Twin Motorcycles Buell Support forever.

the new muller clutch comes a assembly pack — bijTwin Motorcycles Buell Support forever.

you see the differance in lenght in the arm, hence the lesser force is needed on the lever — bij Twin Motorcycles Buell Support forever.

balls and clip on — bij Twin Motorcycles Buell Support forever.

and back in the primary , adjusting it needs 1/8 turn loose instead off the 1/4 turn with stock one , feels allot lighter , she will love it 🙂 — bij Twin Motorcycles Buell Support forever.

M2 rerouting the electrical connections — bij Twin Motorcycles Buell Support forever.

stator plug secure this with a ziptie — bij Twin Motorcycles Buell Support forever.

and the ground wire needs to go on the back off the regulator — bij Twin Motorcycles Buell Support forever.

make sure the ground is good and clean — bij Twin Motorcycles Buell Support forever.

starter motor back in — bij Twin Motorcycles Buell Support forever.

shock assembly loosely fitted , first the oil lines to the pump back on — bij Twin Motorcycles Buell Support forever.

oil lines and wires fixed — bij Twin Motorcycles Buell Support forever.

and the rest off the shock levers can be mounted — bij Twin Motorcycles Buell Support forever.

timing cover back on — bij Twin Motorcycles Buell Support forever.

base setting.. back to markings we took it off.. checking this when the electrics are fuctional again— bij Twin Motorcycles Buell Support forever.

front engine tie rod back on — bij Twin Motorcycles Buell Support forever.

top tie rod on, and stenzel stutte mounted — bij Twin Motorcycles Buell Support forever.

manifold on the bike — bij Twin Motorcycles Buell Support forever.

and nice HSR ready to be mounted — bij Twin Motorcycles Buell Support forever.

lining up the front bracket before you tighen it — bij Twin Motorcycles Buell Support forever.

and a little hydro loctite on these bolts ( XB breather conversion so these bolts are just bolts, no hollow breather plugs — bij Twin Motorcycles Buell Support forever.

tight fit to the cooling ribs 🙂 — bij Twin Motorcycles Buell Support forever.

camcover cover breathing hose and electrics sorted— bij Twin Motorcycles Buell Support forever.

and header back on… come with nordloc washers… they have been loosened to many times as the sharp edges off the lock ramps are worn off , the still work some what… and i tighten the header with out tension anyway — bij Twin Motorcycles Buell Support forever.

rear tierod and engine ground back on — bij Twin Motorcycles Buell Support forever.

and right foot peg assembly on the bike tighten these lightly so the counter nut in the rear locks and douse not spin when you try to tighten the screw — bij Twin Motorcycles Buell Support forever.

and lower bolt in, with a little locktite — bij Twin Motorcycles Buell Support forever.

primairy drive back on — bij Twin Motorcycles Buell Support forever.

weaping shifter seal , will put a new one in — bij Twin Motorcycles Buell Support forever.

primairy cover back on loctite and tighten to tq — bijTwin Motorcycles Buell Support forever.

oil and pull rod on the pressure plate — bij Twin Motorcycles Buell Support forever.

some clutch cables just don;t have enough free play in the cable adjuster to get a good reading on the ball and ramp mechanisme to feel it is lightly binding , unhooking the cable from the lever will help — bij Twin Motorcycles Buell Support forever.

now i can feel it better — bij Twin Motorcycles Buell Support forever.

cover on nice — bij Twin Motorcycles Buell Support forever.

and left foot peg — bij Twin Motorcycles Buell Support forever.

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=950

1-9-2016: finishing jobs… very bussy taking phone calls and visiters in the shop, so little thinker time today

Source: TWIN Motorcycles

1-9-2016: finishing jobs… very bussy taking phone calls and visiters in the shop, so little thinker time today

last thing i needed to do on the bigbore… change battery as a bigass workshop battery was mounted to crank the engine , for testing ok.. but the seat cannot be mounted like this

and the X3 Li-ion battery is much smaller, i can put the ground back on the left side

this baby packs a punch 300 Cold cranking amps , and you see how small it is ( and light )

she is ready for here trip back to the UK

XB12 S/R conversion running way to hot… we already replaced the engine temp sensor as it was out off fase with,

always a way to do it right, grounds to the ecm are still ok

but the wire harness to the temp sensor and O2 sensor was showing some problems

after fixing the wire loom , fan action again on the right temperature , and O2 sensor gives a normal value again 🙂

so test riding… perfect and with the right air scoop the fan douse not come on even after shutting down the bike , and the engine stays in normal operation temeratures

wind buffing Uly… i know from experance people with a surten lenght have this problem with the original high screen

with the zero gravity screen you will not have this problem

engine back in

there are many way to put in back in, i find it the most easy to loosen the isolator and lift the frame , slide the swingarm assembly back a little so the engine will not interfear with the frame

mounting bolts in

and lifting / lowering the frame over the engine

isolator bolts back in place

and front mount back on, put some red loctite on the headbolts

and tq these down as these bolts are only strong when there in the right tension

stenselstutte back on and isolator bolt back on

technoflex suspention brace on

i noticed a little dent in the casings , one off the bolts is to long off the techno flex

litle grinding tot he mount bolts , just nicer

and the hinge mechanisme is back on

 

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=949