What did we do today 15-2-2017 Xb12SS 2009 big inspection and leaking base gasket

What did we do today 15-2-2017 Xb12SS 2009 big inspection and leaking base gasket

Source: TWIN Motorcycles

What did we do today 15-2-2017 Xb12SS 2009 big inspection and leaking base gasket

i lost the pictures iff the start off this service… so i pick up half way… oily parts already done — bij Twin Motorcycles Buell Support forever.

hidden rear caliper mounted — bij Twin Motorcycles Buell Support forever.

looks very clean… like this — bij Twin Motorcycles Buell Support forever.

on request customer i made the brake line realy hidden ( below the swingarm ) and up though the space between the engine and the swing arm ( with some extra protection on the brake line ) — bij Twin Motorcycles Buell Support forever.

no it douse not brake better… only looks nice 🙂 — bij Twin Motorcycles Buell Support forever.

customer asked to mount fully sinterpads right away— bij Twin Motorcycles Buell Support forever.

so some sinter ones mounted — bij Twin Motorcycles Buell Support forever.

little drop off loctite on the mounting bolts — bij Twin Motorcycles Buell Support forever.

brake line to the master rear — bij Twin Motorcycles Buell Support forever.

connected and brake light switch connector can be mounted back — bij Twin Motorcycles Buell Support forever.

rear wheel bearings started to feel gritty… replaced these — bij Twin Motorcycles Buell Support forever.

if your carefull the hidden caliper set up makes it faster to mount the rear wheel. as the caliper can stay in place , for mounting opening up the space between the brake pads can be usefull — bij Twin Motorcycles Buell Support forever.

filling the rear fluid — bij Twin Motorcycles Buell Support forever.

bleeding can be a pain… with a vacuum pump.. easy peasy — bij Twin Motorcycles Buell Support forever.

looks like the front cylinder base gasket is sweating a little — bij Twin Motorcycles Buell Support forever.

replaced the broken spring in the belt tensioner — bij Twin Motorcycles Buell Support forever.

removing the rear straps to take off the exhaust — bij Twin Motorcycles Buell Support forever.

with the tensioner removed is much easier — bij Twin Motorcycles Buell Support forever.

exhaust off — bij Twin Motorcycles Buell Support forever.

supporting the engine — bij Twin Motorcycles Buell Support forever.

and removing the front engine bolt — bij Twin Motorcycles Buell Support forever.

front header bolts loose — bij Twin Motorcycles Buell Support forever.

no to the top , airbox need to come off — bij Twin Motorcycles Buell Support forever.

mnnnn… not to happy about this ( the oversize honed cylinders are only just broken in ) base plate off — bij Twin Motorcycles Buell Support forever.

removing the side stand , the reasr off the bike is already lowered… and we need to lower the front end to… a shorter side stand is very smart , as the bike will stand to upright — bij Twin Motorcycles Buell Support forever.

long one off, short one on — bij Twin Motorcycles Buell Support forever.

little lubing wil not hurt the dry pivot — bij Twin Motorcycles Buell Support forever.

so further with the engine rotation , disconnect the reasr O2 sensor — bij Twin Motorcycles Buell Support forever.

and rotate the engine down so you can loosen the header nuts — bij Twin Motorcycles Buell Support forever.

a little wiggeling and pulling , and the header is off— bij Twin Motorcycles Buell Support forever.

intake manifold flange bolts loose — bij Twin Motorcycles Buell Support forever.

and spark plugs the easy way ( with engine rotated down ) — bij Twin Motorcycles Buell Support forever.

as i want the remove the front head / cilinder to check , the top mount and coil bracket needs to come off — bij Twin Motorcycles Buell Support forever.

manifold out — bij Twin Motorcycles Buell Support forever.

need to adress this.. rubbing wire harness problem to be — bij Twin Motorcycles Buell Support forever.

so off with the heads , starting with the rocker cover— bij Twin Motorcycles Buell Support forever.

rocker box bolts… start with the 6 small ones — bij Twin Motorcycles Buell Support forever.

place a little rag between the head and the rocker box… it will leak oil there … loosen evenly the 4 big rocker box bolts — bij Twin Motorcycles Buell Support forever.

pushrods out — bij Twin Motorcycles Buell Support forever.

and with a 1/2 inch 12 point you can loosen / remove the head bolts — bij Twin Motorcycles Buell Support forever.

mnnn not good.. i now know why the base is sweating.. headgasket failure , and head bolt came loose ( with out the tension… ) need to check the cylinder studs… we don’t see this happen often , it even looks like the head gasket was leaking a little— bij Twin Motorcycles Buell Support forever.

some markings in the cilinder — bij Twin Motorcycles Buell Support forever.

piston and rings look good… looks like the 2e ring is not even worn in fully — bij Twin Motorcycles Buell Support forever.

case protected from falling objects , and lifters protected — bij Twin Motorcycles Buell Support forever.

after looking at the front i really need to check the reas to , about the same as the front.. but with a head sensor in the middle off the head.. loosen this connector — bij Twin Motorcycles Buell Support forever.

small bolts fist than big bolts evenly — bij Twin Motorcycles Buell Support forever.

and the head bolts loose, these where all nive and tight — bij Twin Motorcycles Buell Support forever.

rear head off, you see the gasket has sticked on all around.. typical witht he stock gaskets , signs off a good seal — bij Twin Motorcycles Buell Support forever.

resr rings look also ok.. hardly worn in… i will give the cylinders a light hone to sharpen up the cylinders, new rings.. and will break here in on the dyno my self , with break in oil — bij Twin Motorcycles Buell Support forever.

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=1025

What did we do today 10-2-2017 Uly inspection fuel pump and belt tensioner service , Uly clutch cable fix

What did we do today 10-2-2017 Uly inspection fuel pump and belt tensioner service , Uly clutch cable fix

Source: TWIN Motorcycles

What did we do today 10-2-2017 Uly inspection fuel pump and belt tensioner service , Uly clutch cable fix

at first you think it is a 06 model… but this is a 2008 XB12X in for check up and fuel pump replacement — bij Twin Motorcycles Buell Support forever.

as the customer needed to use a heavier fuse as the normal one kept burning ( fuel pump draws to uch current ) — bij Twin Motorcycles Buell Support forever.

but first intake leak test … still good — bij Twin Motorcycles Buell Support forever.

so while the oil is draining , removing the covers… missing screw spotted — bij Twin Motorcycles Buell Support forever.

mnnn will fix this pully cover has not been given enough space for the belt tensioner .. and has been rubbing on the idler pully — bij Twin Motorcycles Buell Support forever.

with the spring loaded tensioner, this is about where you want to cut the clearance in the cover — bij Twin Motorcycles Buell Support forever.

rusty… yep they do…. the stock exhaust are made off low carbon steel and will corrode — bij Twin Motorcycles Buell Support forever.

gearbox drain plug… very little debris… carefull rider :- ) — bij Twin Motorcycles Buell Support forever.

see if i can save the clutch cable — bij Twin Motorcycles Buell Support forever.

belt is starting to wear ( note the markings between the theet ) — bij Twin Motorcycles Buell Support forever.

gearbox oil back in — bij Twin Motorcycles Buell Support forever.

replacing the oil filter — bij Twin Motorcycles Buell Support forever.

brake pads need replacement — bij Twin Motorcycles Buell Support forever.

rear axle needed the trusty breaker bar — bij Twin Motorcycles Buell Support forever.

i hear the belt tensioner squeel when it moves.. i will take it off and clean / relube — bij Twin Motorcycles Buell Support forever.

bearings are soso… the feel loose , best to not take changes .. replaced these when in dought — bij Twin Motorcycles Buell Support forever.

mnn the tensiner is spacered , but not enough. — bij Twin Motorcycles Buell Support forever.

as the arm still hit the exhaust bracket — bij Twin Motorcycles Buell Support forever.

ok take this apart… you can remove 1 screw — bij Twin Motorcycles Buell Support forever.

and take the bolt with spring out — bij Twin Motorcycles Buell Support forever.

and it comes apart — bij Twin Motorcycles Buell Support forever.

there is a bearing bushing in the middle mount — bij Twin Motorcycles Buell Support forever.

but a little grease to the sides will help.. as this one has been rubbing — bij Twin Motorcycles Buell Support forever.

and the spring broke off 1 winding — bij Twin Motorcycles Buell Support forever.

so little cleaning… note how smal the movement is limited ( the oval slot ) — bij Twin Motorcycles Buell Support forever.

cleaned relubed and new spring — bij Twin Motorcycles Buell Support forever.

put loctite on the screw and tension it slowly, and fee the movement ( to tight and it will stick ) — bij Twin Motorcycles Buell Support forever.

cleaned the studs from corrrosion.. and she can go back on — bij Twin Motorcycles Buell Support forever.

filling oil../ something touratech ( lugage rack ) did not really think off — bij Twin Motorcycles Buell Support forever.

now fuel pump. airbox removed , and fuel line disconnect and i connected my drain hose to it — bij Twin Motorcycles Buell Support forever.

go to testing mode… and test cycle the fuel pump untill it is empty — bij Twin Motorcycles Buell Support forever.

swing arm axle pinch bolt loose — bij Twin Motorcycles Buell Support forever.

and axle loose , so the swingarm can be pulled a little to the right — bij Twin Motorcycles Buell Support forever.

left foot peg bracket off — bij Twin Motorcycles Buell Support forever.

disconnect the fuel pump connector — bij Twin Motorcycles Buell Support forever.

and remove the fuel line — bij Twin Motorcycles Buell Support forever.

the 4 bolts out the fuel pump cover, you can use 1 in the middle to pull the pump out — bij Twin Motorcycles Buell Support forever.

slowly, and note it will still spill some fuell — bij Twin Motorcycles Buell Support forever.

rear shock bolt out — bij Twin Motorcycles Buell Support forever.

so the pump will clear the swing arm and you don’t damage it — bij Twin Motorcycles Buell Support forever.

the c-clip on the rod needs to come off to pull off the regulator housing — bij Twin Motorcycles Buell Support forever.

we are going to replace the regulator and filter to on this one.. remove the white lock ring — bij Twin Motorcycles Buell Support forever.

and genlty pull out the regulator — bij Twin Motorcycles Buell Support forever.

old pump out the holder — bij Twin Motorcycles Buell Support forever.

fuel filter out.. note these have a flow direction — bij Twin Motorcycles Buell Support forever.

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

and pump filter back on the pump base — bij Twin Motorcycles Buell Support forever.

o-rings on the new regulator — bij Twin Motorcycles Buell Support forever.

and lock ring in place — bij Twin Motorcycles Buell Support forever.

press the regulator housing down… and push the c-clip in one off the slots — bij Twin Motorcycles Buell Support forever.

ground screw back in — bij Twin Motorcycles Buell Support forever.

the old o-ring are so swolen they will never go back in .. — bij Twin Motorcycles Buell Support forever.

new o-rings and little mounting silicone grease — bij Twin Motorcycles Buell Support forever.

and pump back in , pull it in evenly with the 4 mounting screws — bij Twin Motorcycles Buell Support forever.

and pump back in , pull it in evenly with the 4 mounting screws — bij Twin Motorcycles Buell Support forever.

some protection used when the swingarm was resting on the exhaust tip — bij Twin Motorcycles Buell Support forever.

axle back in — bij Twin Motorcycles Buell Support forever.

and set to 66 NM — bij Twin Motorcycles Buell Support forever.

and tighten the pinch bolt — bij Twin Motorcycles Buell Support forever.

shock mounted back — bij Twin Motorcycles Buell Support forever.

new bearings… and wheel can go back in — bij Twin Motorcycles Buell Support forever.

tensioner mounted… no more squiky noise — bij Twin Motorcycles Buell Support forever.

ok next job… rear brake — bij Twin Motorcycles Buell Support forever.

as it is wearing a little uneven i will take out the slide pin and clean it — bij Twin Motorcycles Buell Support forever.

the boot is sti;; good — bij Twin Motorcycles Buell Support forever.

cleaned out he hole, and press in new grease , press the pin in a few times to spread the grease — bij Twin Motorcycles Buell Support forever.

fresh pads on… — bij Twin Motorcycles Buell Support forever.

footpeg bracket back on… the fuel breather line runs in the hole — bij Twin Motorcycles Buell Support forever.

usualy eayer to first put the lugage rack screw in and than thighten the 3 mount screws — bij Twin Motorcycles Buell Support forever.

front plug out — bij Twin Motorcycles Buell Support forever.

some rubbing marks… still ok — bij Twin Motorcycles Buell Support forever.

the connectors where very deep in the plug boot… and felt like they where not clicked “on” — bij Twin Motorcycles Buell Support forever.

rear plug out swivel and extention is needed — bij Twin Motorcycles Buell Support forever.

pull the plug connectors out the boot, — bij Twin Motorcycles Buell Support forever.

so you can see your clicking theme on — bij Twin Motorcycles Buell Support forever.

than pull the boot down and turn it inwards to it is not running to any wires — bij Twin Motorcycles Buell Support forever.

the exhaust solinoid has a historical error… we desided to turn the valve open and disable the soliniod in the ecm , as i really don’t feel like to remove a very rusty exhaust.. i cobble up something to the valve stays open — bij Twin Motorcycles Buell Support forever.

right front side check — bij Twin Motorcycles Buell Support forever.

needs new pads — bij Twin Motorcycles Buell Support forever.

so loosen the pad holding pin while the caliper bolts are still in — bij Twin Motorcycles Buell Support forever.

very hard to mis 2008 -up uly front fork — bij Twin Motorcycles Buell Support forever.

wheel bearings feel also loose , i will replace these to — bij Twin Motorcycles Buell Support forever.

you can rattle theme.. — bij Twin Motorcycles Buell Support forever.

wheel back in and fresh brake pads on — bij Twin Motorcycles Buell Support forever.

front brakes feels cruncy when you pull it , sign old hard grease on the point where the piston toughes the lever — bij Twin Motorcycles Buell Support forever.

use heat to loosen the loctite before you even try to loosen the windguard screws , if they have never been out — bij Twin Motorcycles Buell Support forever.

dry pivot — bij Twin Motorcycles Buell Support forever.

little cleaning and some resh silicone grease , so much differance in feel — bij Twin Motorcycles Buell Support forever.

fresh brake fluid front — bij Twin Motorcycles Buell Support forever.

and rear — bij Twin Motorcycles Buell Support forever.

some new spare fuses in the box.. and replace the 15 a for the normal 10 A for the fuel pump — bij Twin Motorcycles Buell Support forever.

uly with rack… check the seat spar bolts ones in a while — bij Twin Motorcycles Buell Support forever.

battery connections check — bij Twin Motorcycles Buell Support forever.

disabeling the exhaust servo — bij Twin Motorcycles Buell Support forever.

and uncheck the error light for it — bij Twin Motorcycles Buell Support forever.

warming up the bike for oil level check — bij Twin Motorcycles Buell Support forever.

and testing heated grips — bij Twin Motorcycles Buell Support forever.

left one — bij Twin Motorcycles Buell Support forever.

right one working a little uneven — bij Twin Motorcycles Buell Support forever.

checking oil level — bij Twin Motorcycles Buell Support forever.

and test ride 🙂 she is ready to travel over the Alps again — bij Twin Motorcycles Buell Support forever.

thorn in my eye.. for some time… leaking clutch cable — bij Twin Motorcycles Buell Support forever.

on a very nice Uly 😉 — bij Twin Motorcycles Buell Support forever.

it has been some time the last time i used this bike.. but there is still watter in the adjuster booth that was cracked — bij Twin Motorcycles Buell Support forever.

to have better acces… i remove the brace — bij Twin Motorcycles Buell Support forever.

problem when they leak.. the outer cable is no longer connected to the metal fitting , i could turn this by hand.. the cable over all is not bad… no wires breaking, so worth a repair — bij Twin Motorcycles Buell Support forever.

clean and relube the outer adjuster — bij Twin Motorcycles Buell Support forever.

heat shrinking the repair tube over it , the glue in side is heat activated — bij Twin Motorcycles Buell Support forever.

cable and back in the lever — bij Twin Motorcycles Buell Support forever.

and she will not leak any more 🙂 — bij Twin Motorcycles Buell Support forever.

 

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=1024

9-2-2017 front Brake disk ,fork seal, inspection XB rear tyre and disk

9-2-2017 front Brake disk ,fork seal, inspection XB rear tyre and disk

Source: TWIN Motorcycles

9-2-2017 front Brake disk ,fork seal, inspection XB rear tyre and disk

the 1125r came in suspected the brake pad need replaceing — bij Twin Motorcycles Buell Support forever.

looking at the disk… he was a little late — bij Twin Motorcycles Buell Support forever.

pads been worn down metal to metal — bij Twin Motorcycles Buell Support forever.

it still brakes, not nice , but it brakes — bij Twin Motorcycles Buell Support forever.

there all down to the last half mm — bij Twin Motorcycles Buell Support forever.

front wheel bearings are good to go — bij Twin Motorcycles Buell Support forever.

nice new disk on, bolt to 35 Nm — bij Twin Motorcycles Buell Support forever.

new disk, new pads , push the pads in so the holder pin moves in freely — bij Twin Motorcycles Buell Support forever.

aline the caliper slots with the sokes — bij Twin Motorcycles Buell Support forever.

caliper bolts to 55 Nm — bij Twin Motorcycles Buell Support forever.

pump the brake to pressure and tighten the pad pins — bij Twin Motorcycles Buell Support forever.

push in the suspention a few time to set the front forks.. — bij Twin Motorcycles Buell Support forever.

and tighen the pinch bolts — bij Twin Motorcycles Buell Support forever.

she will get to 150K this year , little leak on the right front fork — bij Twin Motorcycles Buell Support forever.

she is not the nicest lady off the dance anymore, but she has lots off experiance — bij Twin Motorcycles Buell Support forever.

starting to show the miles — bij Twin Motorcycles Buell Support forever.

spong a leak , right oil seal — bij Twin Motorcycles Buell Support forever.

so fork ready to be removed, remove the Special pro series limited edition horn — bij Twin Motorcycles Buell Support forever.

and take the leg out — bij Twin Motorcycles Buell Support forever.

still be carefull with the cap nuts, these mark very hard and easy — bij Twin Motorcycles Buell Support forever.

old oil out — bij Twin Motorcycles Buell Support forever.

and retaining clip loose — bij Twin Motorcycles Buell Support forever.

use the slider as pull hammer and knock the oil seal out… with this km done, i replace the guide bushings anyway… as they starting to wear out — bij Twin Motorcycles Buell Support forever.

some pitting on the leg.. in a low region… it the leak returns to quickly, we need to replace the slider— bij Twin Motorcycles Buell Support forever.

wrap the top end ( read sharp edges ) off the fork slider with electrical isolation tape , not to damage the new seals — bij Twin Motorcycles Buell Support forever.

retainer clip on the dust seal, will not scratch like this — bij Twin Motorcycles Buell Support forever.

new bushings on — bij Twin Motorcycles Buell Support forever.

hammer the seal in place and clip the retainer in place — bij Twin Motorcycles Buell Support forever.

front fork back in — bij Twin Motorcycles Buell Support forever.

and wheel back in — bij Twin Motorcycles Buell Support forever.

caliper and fender on. and she is ready to go again— bij Twin Motorcycles Buell Support forever.

Xb12SS litle check up and new rear tyre — bij Twin Motorcycles Buell Support forever.

mnnn notice the neutral light switch is not working— bij Twin Motorcycles Buell Support forever.

yes better to replace for the season — bij Twin Motorcycles Buell Support forever.

so rear caliper off — bij Twin Motorcycles Buell Support forever.

and rear wheel out… check the bearings everytime you hold the wheel !!! these are ok — bij Twin Motorcycles Buell Support forever.

with the wheel out, and belt pulled off the pully… locating the neutral switch wire to see what is happening — bij Twin Motorcycles Buell Support forever.

she is not making pixies , openloop — bij Twin Motorcycles Buell Support forever.

thinned out 5/8 high socket , under a angle but you can get the switch out , there not stupid tight — bij Twin Motorcycles Buell Support forever.

don’t forget to take out the crush washer — bij Twin Motorcycles Buell Support forever.

new switch in… contact !!! — bij Twin Motorcycles Buell Support forever.

belt and wheel back in and tq the rear axle 66 NM— bij Twin Motorcycles Buell Support forever.

mnnn strange… still work… little stiff feeling ( will check the other settings — bij Twin Motorcycles Buell Support forever.

normaly the axle douse not stick out.. — bij Twin Motorcycles Buell Support forever.

she wat happens whe i loosen the pich bolts and axle — bij Twin Motorcycles Buell Support forever.

axle is flush now.. while we turned it out… front is not very happy put to getter — bij Twin Motorcycles Buell Support forever.

ok brake stutter… i could almost see this one by eye, but a sharpy makes more visible , spin off the front wheel and here is is already toughing the middle — bij Twin Motorcycles Buell Support forever.

1/4 turn away much less — bij Twin Motorcycles Buell Support forever.

lightly aplying the brake and turn the wheel , here almost full contact on the disk — bij Twin Motorcycles Buell Support forever.

half a turn away no such thing.. we can safely say the disk is warped — bij Twin Motorcycles Buell Support forever.

caliper bolts heavy corroded… i will put some nice ones in — bij Twin Motorcycles Buell Support forever.

the front wheel bearings feel also very loose and starting to feel gritty — bij Twin Motorcycles Buell Support forever.

some new ones in, works so much better — bij Twin Motorcycles Buell Support forever.

old disk off — bij Twin Motorcycles Buell Support forever.

and new disk on… again 35 Nm on the bolts — bij Twin Motorcycles Buell Support forever.

temporary mounting back the caliper as a vise to loosen the pad pin — bij Twin Motorcycles Buell Support forever.

new disk / new pads… these are out — bij Twin Motorcycles Buell Support forever.

wheel back in… new bolts with some loctite — bij Twin Motorcycles Buell Support forever.

and tighten the front axle , press down the suspention a few times and tighten the pinch bolts— bij Twin Motorcycles Buell Support forever.

cleanng off the greasy thumbprints before you start braking — bij Twin Motorcycles Buell Support forever.

good / bad battery ? it is low 125 cca is low , will see how it starts — bij Twin Motorcycles Buell Support forever.

interseting repair on the side rails passenger peg brackets — bij Twin Motorcycles Buell Support forever.

low CCA on the battery could also be a loose connection , the top on is good — bij Twin Motorcycles Buell Support forever.

but the one directly to the battery is loose, i retighten these and put the bike under a smart charger — bij Twin Motorcycles Buell Support forever.

what happens when you put a XB 6 pot brake lever on a X1 … to much play on the lever… and a disco brake light as the lever ratteling will make the brake light rattle to — bij Twin Motorcycles Buell Support forever.

other one fitted… with the correct specs… works — bij Twin Motorcycles Buell Support forever.

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=1023

What did we do Today 8-2-2017 Big inspection XB12SS , Sportster 48 front wheel

What did we do Today 8-2-2017 Big inspection XB12SS , Sportster 48 front wheel

Source: TWIN Motorcycles

What did we do Today 8-2-2017 Big inspection XB12SS , Sportster 48 front wheel

very nice Xb12SS in for its first big inspection

she came in hot, so draining the fluids right way — bij Twin Motorcycles Buell Support forever.

in the mean while striping al the covers to have a look under there — bij Twin Motorcycles Buell Support forever.

primairy drain plug… yes is normal — bij Twin Motorcycles Buell Support forever.

chewy screws are not, i will replace this one — bij Twin Motorcycles Buell Support forever.

old model side stand pivot … ( this is early 06 model ) check theme , this one was loose, if left alone you will find your bike on the ground on day ( as the side stand will fail ) — bij Twin Motorcycles Buell Support forever.

clean the threads in the side stand — bij Twin Motorcycles Buell Support forever.

and the pin, fresh lube and red loctite , if left to dry , it will not come loose again — bij Twin Motorcycles Buell Support forever.

pulling the spring back on , a spring puller is very usefull — bij Twin Motorcycles Buell Support forever.

removing the left airscoop to get to the spark plugs— bij Twin Motorcycles Buell Support forever.

new oil filter on, primed and o-ring wet, hand tight— bij Twin Motorcycles Buell Support forever.

trying to adjust the clutch cable… no dice. corroded solid , i think power washer watter.. as the bike has not seen allot off rain , — bij Twin Motorcycles Buell Support forever.

on with the service, inspecting the primairy chain tension… ok — bij Twin Motorcycles Buell Support forever.

front plug out… from below — bij Twin Motorcycles Buell Support forever.

check the gap on your new plugs.. ususaly they are set to tight out off the factory — bij Twin Motorcycles Buell Support forever.

old clutch cable out the lever — bij Twin Motorcycles Buell Support forever.

front bracket loose — bij Twin Motorcycles Buell Support forever.

and you can screw out the clutch cable — bij Twin Motorcycles Buell Support forever.

new cable in, o-ring on.. the cables come with some loctite sealant on there, don’t over tighten these, the hollow bolts breaks very fast — bij Twin Motorcycles Buell Support forever.

prepairing the new clutch cable by putting some neverseas on the adjuster — bij Twin Motorcycles Buell Support forever.

and clutch ramp / bal back on adjusting lightly botteming and back of a 1/4 turn — bij Twin Motorcycles Buell Support forever.

cable mount brackets on the cable and feed it thought the triple t — bij Twin Motorcycles Buell Support forever.

front bolt back on — bij Twin Motorcycles Buell Support forever.

ziptie the regulator cables back on — bij Twin Motorcycles Buell Support forever.

adjusting. the outer cable, double security.. some small zipties on bought end off the booth — bij Twin Motorcycles Buell Support forever.

rear inspection … belt shows light cracking, and some keflar koord was ripped out. still being the first belt, customer wanted it to be replaced, smart— bij Twin Motorcycles Buell Support forever.

so brace loose from the swing arm , and replace the belt — bij Twin Motorcycles Buell Support forever.

before you tighten the rear axle, the swingarm brace needs to be inplace — bij Twin Motorcycles Buell Support forever.

and don’t forget the pich bolt — bij Twin Motorcycles Buell Support forever.

pully cover back on, light coat off neverseas, as i could see the dry corrosion on it — bij Twin Motorcycles Buell Support forever.

the Rizoma rear set in front position has left some marks on the pully cover ( the bolts stick out a little ) — bij Twin Motorcycles Buell Support forever.

working my way up… rear spark plug.. and cable check , these are still fine — bij Twin Motorcycles Buell Support forever.

air filter how ever… not , replaced this one by a K&N filter — bij Twin Motorcycles Buell Support forever.

customer could see sparks under the seat ? mnnn did not check the battery cables — bij Twin Motorcycles Buell Support forever.

+ is loose — bij Twin Motorcycles Buell Support forever.

the washer under the screw head is spark erododed away — bij Twin Motorcycles Buell Support forever.

and the battery has signs to show it, check these.. the battery rattles under the seat… and can couse the cables to come loose — bij Twin Motorcycles Buell Support forever.

time for the front end — bij Twin Motorcycles Buell Support forever.

front wheel bearings are fronzen on the front axle… no biggy, tap with some protection the right leg with a mallet , normaly the come loose — bij Twin Motorcycles Buell Support forever.

you see the marks where the bearing was stuck on— bij Twin Motorcycles Buell Support forever.

front legs out , for service — bij Twin Motorcycles Buell Support forever.

use some isolation tape to protect the top cap nuts , they are very fragile — bij Twin Motorcycles Buell Support forever.

before you colaps the front fork.. clean the bottom ends, the seals will live longer — bij Twin Motorcycles Buell Support forever.

checking the rebound settings before i break the connection — bij Twin Motorcycles Buell Support forever.

drain , rinse and fill with fresh oil, bleed the rebound damper tube untill the up and down stroke are controled the full way — bij Twin Motorcycles Buell Support forever.

indexing the adjuster screw.. flat and points matching… is fully closed , this way i know for sure i have the full adjustment range — bij Twin Motorcycles Buell Support forever.

front end back on, axle cleaned and coated with lubrication — bij Twin Motorcycles Buell Support forever.

brake fluid from 2005 ? best to replace every year— bij Twin Motorcycles Buell Support forever.

so fresh front — bij Twin Motorcycles Buell Support forever.

don’t forget the rear… ready for a cold test ride :-)— bij Twin Motorcycles Buell Support forever.

48 front wheel back from the wheel guy… new nippels and inline — bij Twin Motorcycles Buell Support forever.

no i don’t like inner tyres 😉 — bij Twin Motorcycles Buell Support forever.

checking the balance on the wheel , fat tyres , heavy wheel… the wheel guy did good.. need only 25 gramms 🙂 — bij Twin Motorcycles Buell Support forever.

wheel back in… caliper back on — bij Twin Motorcycles Buell Support forever.

pinch bolt on — bij Twin Motorcycles Buell Support forever.

and the axle caps — bij Twin Motorcycles Buell Support forever.

nice wheel is centered now — bij Twin Motorcycles Buell Support forever.

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=1022

28-1-2017 Assembly Buell XB cases, Custom Buell XB wire harness

28-1-2017 Assembly Buell XB cases, Custom Buell XB wire harness

early moning request if we could press the gear box and and close the case on the engine , as the customer is rebuilding the rest him self, off course no problem

first will remove the shift fork sliders

you can do this with a punch on the other side off the case there are notches to do so

pressing in… best done “upside down” as the spacers and rings will fall out off position , and this way the bearing c-clips can not be pressed broken ( seen this allot )

gearbox shafts pressed in, put the shift forks back in,

put the slider rods in , and put the shift drum back in , and put the shift forks in the slots off the shifter drum. and tap the slider pipes in the holes in the case to lock theme in place

little tool put in the neutral switch hole to have the detent out the way during mounting

little prelubing with assembly grease

check the cases for burrs , cleaned this off , needs to be flat as possible

some more pry open markings

degreased the gasket surface, small beed of sealant, and crank in position

gently lower the other case half over the gearbox / crank it should fit nice and snug with out needed to hammer it in place ( than there is something wrong )

thighten the case bolts starting from the middle so they are all hand tight

detent tool removed, and try the gearbox if it moves smoothly in each gear , with a flat screw driver you can turn the shifter drum

and setting the TQ on the case bolts

counter shaft lock bolt, put some red loctite on it

cleaned off the left crank spacer, and she is ready to be assembled by the owner

wire harness… little to see, trying to get the most out off the wire loom, rerouting thebrake light switch wires.. i can remove the old ones that are fixed to the switch.. as the stock ones in the harness are long enough

for now.. these need to be conencted

opening up the speedo connector

and removing all that is not needed

checking connections and working off the non stock indicator switch

and testing … putting power to a portion off the harness, ok indicators done..

 

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=1019

Source: TWIN Motorcycles

27-1-2017 Custom Buell XB12 wire harness, heated grips XB12X

What did we do today: 27-1-2017 Custom Buell XB12 wire harness, heated grips XB12X

with a new flange, the intake can be put back on — bij Twin Motorcycles Buell Support forever.

very easy with the frame lifted 🙂 — bij Twin Motorcycles Buell Support forever.

lowering the frame just a bit to connect the startermotor cable — bij Twin Motorcycles Buell Support forever.

speed sensor connector ( lock is on the back side ) connected and screw back in — bij Twin Motorcycles Buell Support forever.

lining up the rear mount to put the bolt back on — bij Twin Motorcycles Buell Support forever.

now first the front wheel back in so it lands on its feet — bij Twin Motorcycles Buell Support forever.

front in, engine still down — bij Twin Motorcycles Buell Support forever.

cable harness guide need to be reused, — bij Twin Motorcycles Buell Support forever.

routing the head sensor, rear o2 and manifold wires in the guide so the will not rub — bij Twin Motorcycles Buell Support forever.

and engine back up — bij Twin Motorcycles Buell Support forever.

set to 66Nm — bij Twin Motorcycles Buell Support forever.

with the engine in place also re tighten the rear mount bolt to 66 Nm — bij Twin Motorcycles Buell Support forever.

breather oil line back in the cover — bij Twin Motorcycles Buell Support forever.

and mount the oil line support — bij Twin Motorcycles Buell Support forever.

ziptie the gearbox breather hose away from the header — bij Twin Motorcycles Buell Support forever.

and rear tierod with some red loctite back on — bij Twin Motorcycles Buell Support forever.

needed to cut the protective rubber for the battery cable, feeding this thought the swingarm ( battery is inside the swing arm ) — bij Twin Motorcycles Buell Support forever.

shcok back on for now, fan still out so we can still ad cables iff needed tough the frame opening — bijTwin Motorcycles Buell Support forever.

now the fun starts… stripping the wire loom — bij Twin Motorcycles Buell Support forever.

and removing all that is not needed… like exhaust solinoid wiring — bij Twin Motorcycles Buell Support forever.

press the white tab to unlock the connenctor — bij Twin Motorcycles Buell Support forever.

and you can pull out the wires — bij Twin Motorcycles Buell Support forever.

how many grounds to the ecm … allot — bij Twin Motorcycles Buell Support forever.

halfway in the wire harness ( normaly wrapped ) some off the pain spots , all grounds bundled to getter.. important with problems to check all the ground pins in the ecm , don’t asume when you have ground on 1 wire , you have it on all wires — bij Twin Motorcycles Buell Support forever.

TQ hammer back on — bij Twin Motorcycles Buell Support forever.

freed the tension in the connection before tightening the clamp — bij Twin Motorcycles Buell Support forever.

front side dash wireing is useless , as all switches and original speedo is non standard , but i will try to keep the most off the original wiring — bij Twin Motorcycles Buell Support forever.

but some things can be removed. like the clutch switch… as we can also disable this — bij Twin Motorcycles Buell Support forever.

horn wires out, slowly thining the loom — bij Twin Motorcycles Buell Support forever.

removed it from the connector — bij Twin Motorcycles Buell Support forever.

same for the head light.. i need to make a seperate ground anyway, so this one can be removed — bij Twin Motorcycles Buell Support forever.

as is the power out let at the front — bij Twin Motorcycles Buell Support forever.

no to break down the old fabricobbled wire harness— bij Twin Motorcycles Buell Support forever.

problem waiting to happen over time, wire ends tinned.. and than use crimp connectors… a big nono.. i could pull this out with out much effort — bij Twin Motorcycles Buell Support forever.

the LED’s in the left scoop where permanent fixed to the wire harness, some times it is very handy if you can remove this scoop.. so cables cut open and watter tight connector in place — bij Twin Motorcycles Buell Support forever.

the Motogadget scroll button was also hard wired to the bike… so also connector , this is only gound signal — bij Twin Motorcycles Buell Support forever.

hardcore Uly… right hand heated grip was no longer working.. at freezing temp very nice if this works — bij Twin Motorcycles Buell Support forever.

the connectors are behind the fly screen, — bij Twin Motorcycles Buell Support forever.

the oem heated grips are mounted the same as stock , so just 2 screws and you can remove the grip — bij Twin Motorcycles Buell Support forever.

feeding the cable under the dash — bij Twin Motorcycles Buell Support forever.

and ziptie it to the switch in a way when you open the trottle it douse not snag — bij Twin Motorcycles Buell Support forever.

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=1018

Source: TWIN Motorcycles

What did we do Today 25-1-2017 Custom Buell XB12 new wire harness

What did we do Today 25-1-2017 Custom Buell XB12 new wire harness

Source: TWIN Motorcycles

What did we do Today 25-1-2017 Custom Buell XB12 new wire harness

nice custom Xb12 2010 with osilating fuel pump , replacing the wire harness as this is modified so much that trouble shooting is about unpossible — bij Twin Motorcycles Buell Support forever.

hig beam and low beam switches — bij Twin Motorcycles Buell Support forever.

contact and start like a car — bij Twin Motorcycles Buell Support forever.

very nice speedo is mounted

2010 model have a front O2 sensor the wire is kept off the header with the clip

yeah having fun… what color wire

removing the tail section to have some room

start loosening all the sensors, as i want to test the new wire harness before i completely strip the bike

lights LED arrai mounted in the left scoop

crank sensor off

and sidestand switch..i will not mount this one back

could be handy if some one made a connector , commen problem with customs , wired from point to point with out connectors

going to make it a little better — bij Twin Motorcycles Buell Support forever.

top engine sensors connectors off

new harness

comes with relais and fuses

for now , ignition switch and right handle bar switch hooked up to the new wire harness

need to make some power extentions, but it works

and she is smootshing good, fuel pressure is stabile with out ocilating from way to low… so on with the removal off the harness

bike on a lift with a hoist, as i will lift the frame off the swing arm / engine — bij Twin Motorcycles Buell Support forever.

clutch cable loose from the lever — bij Twin Motorcycles Buell Support forever.

single wire throttle cable off

and TQ hammer exhaust off , to have a steady base to support the engine — bij Twin Motorcycles Buell Support forever.

Our Torque Hammer exhaust can be found here

2003-2007 also USA models 2003-2010

2008-2010 European models

 

side stand off, to make it cleaner,

side stand, switch off

looks better like this.. and chin spoiler bracket will not go back on

the regulator wires where also ziptied to the w-brace, i will try to mount this back to the left scoop , so you will not notice these

supporting the bike — bij Twin Motorcycles Buell Support forever.

rear tiebar loose — bij Twin Motorcycles Buell Support forever.

and shock out — bij Twin Motorcycles Buell Support forever.

i will remove the breather oil line, to get to the startermotor wires — bij Twin Motorcycles Buell Support forever.

speed sensor out, and connection to the startermotor off — bij Twin Motorcycles Buell Support forever.

cooling fan out , as the wire harness runs through the frame opening — bij Twin Motorcycles Buell Support forever.

yep… wired from point to point… this one is cut — bij Twin Motorcycles Buell Support forever.

the battery is a LIon cel mounted in the swing arm, a extention is made and the cable is fed through the swing arm — bij Twin Motorcycles Buell Support forever.

craptactic.. and me wondering why the bike needed so much amps to start — bij Twin Motorcycles Buell Support forever.

ok front mount loose , front ens supported — bij Twin Motorcycles Buell Support forever.

in the straps to lift it up — bij Twin Motorcycles Buell Support forever.

mnnn … weldon intake flanges — bij Twin Motorcycles Buell Support forever.

pulling the wire harnes out — bij Twin Motorcycles Buell Support forever.

need to look at the connections made so leave this a little to getter for now — bij Twin Motorcycles Buell Support forever.

replacing a wire harness you will need the plugs new — bij Twin Motorcycles Buell Support forever.

harness back in, little brace back in in the left rear off the frame, gearbox breather hose will go through also — bij Twin Motorcycles Buell Support forever.

as the bike also had a slight leak in the intake seals, and the weldon flange is really not something i would keep on the bike , intake seals.. — bij Twin Motorcycles Buell Support forever.

with the frame lifted… really not much work 🙂 — bij Twin Motorcycles Buell Support forever.

small signs off leaking on the seals ( vacuum bites )— bij Twin Motorcycles Buell Support forever.

not sure ho much time was spend making this old flange to fit the new style heads .. new flange is 8 euro — bij Twin Motorcycles Buell Support forever.

http://www.twinmotorcycles.nl/artikelen.asp?cid=20&aid=1017