Reply With QuoteThanks for the how-to posting. I'm looking at doing the engine rotation to replace the dented header on my '07 9R, and your instructions don't sound too intimidating.
This is a step by step list of how to perform engine rotation on an XB. This is from notes I took in my MMI Buell class. I hope this helps anyone needed to do this job.
1. Remove intake cover, air-box assembly, and intake runner going through frame DO NOT PULL ON VELOCITY STACK, push it down through lower air-box
-remove four silver screws from lower air box
-disconnect IAT sensor and push breather hoses out of lower air-box
-2003-2004 modles, remove two allen fasteners holding velocity stack
-2005 and later models, squeeze and remove circlip holding velocity stack
2. Covr intake port with paper towel/tape
3. Disconnect fuel line, O2 sensor, ET sensor and coil lead, on 2007 and earlier you must also disconnect the TP sensor, 2 fuel injector leads. REMOVE COIL
4. Remove top tie bar fastener from engine (left) side
5. Remove left air scoop and right side engine shroud
6. Remove chin fairing. Turn wheel left and right to gain access to fasteners.
7. Remove left and right side foot peg mounts (three 3/16 allen fasteners suspend right side with bungee
8. Remove clutch cable from perch
9. Loosen rear axle pinch bolt and loosen rear axle 15 rotations or until you see tapered section of axle between swingare and wheel bearing (about 1 1/4 inches out
10. Remove idler pulley and bracket 9/16 scocket
11. On 2003 models only remove inner metal belt guard
12. Tighten rear axel to support rear wheel
13. Remove muffler (7/16 socket) place flat jack under muffler to support it
-loosen torca clamp
- open front strap completely
- remove rear straps
14. Place flat jack under engine cases
- jack should be butted up against kick stand bracket and muffler bracket
- raise jack enough to support motor DO NOT RAISE MOTORCYCLE
15. Remove front "V" (aka "W") bracket from frame (three 3/16 allen fasteners)
16.Remove rear tie bar bolt from frame (right) side DO NOT TOUCH FRONT TIE BAR (from engine case to oil cooler bracket)
17. Loosen rear isolator bolt 1 turn (located about pivot shaft) DO NOT REMOVE
18. Remove front fender
19. Remove front isolator bolt
20. Lower jack to rotate engine down
- let engine rest on front tire
TORQUE SPECS
Air box cover fasteners 12-36 in lbs
Chin fairing fasteners 36-48 in lbs
Foot peg mount fasteners 108-132 in lbs
Front isolator bolt 49-54 ft lbs
Front fender fasteners 12-36 in lbs
Rear axle pinch bolt 40-45 ft lbs
Rear axle 48-52 ft lbs
Muffler strap fasteners (front) 108-120 in lbs
Muffler strap fasteners (rear) 40-60 in lbs
Torca clamp 40-45 ft lbs
Tie bars 25-27 ft lbs
Rear isolator bolt 25-27 ft lbs
Idler pulley 33-35 ft lbs
Sprocket cover 12-36 in lbs
Air horn and Engine shroud 12-36 in lbs
Thanks for the how-to posting. I'm looking at doing the engine rotation to replace the dented header on my '07 9R, and your instructions don't sound too intimidating.
Gotta change my rocker box gasket.
Just the info i will need soon.
Awesome. Thx bro. We were just talkin about this Friday night. I knew it would be alot of work. My buddy said pretty easy. I guess I don't care. He's doin most of the work. Thx again
Its not bad at all I recenty replaced my rocker box gasket on the rear cylinder its pretty to see one rotated out of the bike.
can we make this a sticky?????? this is good knowledge that should be accessible for later reference. good write up!
Stickied this and his other DIY yesterday... They're under the "Do-It-Yourself Buell Mods" section. ;)
Thanks a million! I have been wanting to rotate the engine an remove the headers so they can be properly wrapped in header wrap, just been waiting for the how to. It sounds like a major nut roll to me.
thanks Steven!
One more small bit of info. When rotating the engine back into the frame be sure to watch your wiring and hoses to make sure they don't get pinched in between the engine and frame. The most common is the spark plug wires, if you leave the wires on the plugs (the easiest way) make sure they haven’t fallen down to the side of the engine. It not fun finding something pinched after you have it halfway back together, trust me :)
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