2003 XB9R Rebuild

[charlevoixboy]

Hey all, just picked up an 03 XB9R project bike that I'll be bringing back to life. It's got about 7500 miles on it, and looks like those have been hard miles. Laid down on the left it appears, broken fairing stay, wiring issues, and is only running on 1 cylinder. Guy wanted 2k, I offered $1550 because I couldn't ride it (seems like the kickstand safety switch is bad, will die as soon as clutch begins to be released in any gear or neutral.) First purchases were a Buelltooth, used rear fairing of the right color, grips, and plugs. Will be installing this weekend. I'll update this thread with my progress as I pull the bike down and build it back up! Pretty excited, always wanted a 9r.

 

[charlevoixboy]

 

[Cooter]

Good deal, looks like a super easy project! Keep posting pics, we like pics

 

[charlevoixboy]

Over the weekend I replaced the plugs and got it to fire up, and pulled the codes with the Buelltooth. It showed a "rear o2 always lean" codes and an air temp sensor out of range. Cleared the codes, replaced the 02, reset the tps and reset the fuel trim back to 100 (was at 140 something) and it runs WAYYYY better. After a spin around the block the check engine light popped on for a few seconds and then went back off. Pulled codes again and the rear o2 always lean was back. Cleared it and it hasn't returned. Checked for intake leaks and didn't find anything (used starting fluid around intake when engine was hot.) Leaning towards a potential ground issue. What's also puzzling is the speed sensor, the neutral sensor, and the 02 sensor all are bad. Has me thinking that something is backfeeding where it shouldn't. Will run a dedicated ground from battery to ecm, and from the engine to the frame by where the neg. strap bolts up this weekend.

Also was reading about the 5v regulator in the speed sensor, and was wondering if the speed sponsor part #74402-95B that I have on order had the regulator built in before I go tearing a USB car charger apart. Thanks all!

 

[charlevoixboy]

Looks like it has a K&N

Put the correct color tail on it

Straightening the bar (before)

After

 

[charlevoixboy]

The steering head bearings appear to be toast as well, so those are on order. The parts list to go on is as follows: speedometer sensor, neutral sensor, blinkers, steering head bearings. I also need to recover both seats and need to find a new rear compartment cover and toolkit, as well as the plastic for the undertail (mines cracked.)

 

[34nineteen]

Good work!!!

 

[Cooter]

If you haven't already, the "All Balls" tapered bearings for the steering neck are a good upgrade. The speedo sensor gets a 5v signal, so it doesn't need its own regulator. IIRC 2003 had its own for some reason?

Keep your eye on the AFV just in case theres a different issue, clearing codes only erases the clue, not the problem.

IMHO I would never straighten the clip-on because it's compromised and now fatigued. They are super cheap. Even under $20 from the dealer. SPHDonline.com is a good great source for new OE parts.

XBR seats are the same as 1125 so front and rear are probably cheaper to buy than recover.

 

[Chicknstripn]

I have a spare fuse box and relay cover for an XBr Mine came off and XB12r, I think they’re the same for the 9 and the 12. PM me your address and which one you need, I can’t remember which side is which, and I’ll send it out to ya.
Keep up the good work on the rebuild and diagnostics.

 

[Outlaw]

I see a can of seafoam on that John deer. Is Tea bag helping you ?

 

[MakingPAIN]

I see a can of seafoam on that John deer. Is Tea bag helping you ?

:applause:

 

[charlevoixboy]

I got the clip on pretty hot before tweaking them back, so I'm not too worried. I do appreciate it though! I pulled the covers off both seats and I'm in the process of making new covers for them. I went with a more "grippy" texture, and will be adding foam to the seat as well.

 

[charlevoixboy]

I ordered the bearings from all balls I believe, so hopefully they're the upgraded ones. Old ones are SPOOKY to ride with. Touch the front brake and the front end packs up and more or less reduces the rake and trail to scary numbers I'd imagine. Thanks everyone! I'll continue to update

 

[Cooter]

Theres nothing wrong with re-covering them, especially if you want a specific material. I was just saying it's cheaper to buy those seats. Be sure to use a 'Marine' rated vinyl for outdoor UV protection and mold resistance. It's a bit more money, unless you like re-covering your seats every year

https://www.buellxb.com/forum/showthread.php?53730-Cooter-does-upholstery!

AllBalls will be the tapered style bearings, and better than the OE regular ball bearings:up:

Your choice on the clip-on, but think about $20 vs. what happens if it stress cracks from vibration and fails:upset:

 

[charlevoixboy]

Yeah I may scope out another clip on, I'd hate for it to bust off at the worst possible moment. That'd be my luck. So the consensus is that I should make a 5v regular for the speed sensor? Or is it already getting supplied a clean 5v? The bike is an 03 and idk if it was updated by then or not. Thanks!

 

[Cooter]

You won't need to custom wire anything if you just get a speedo sensor for a 2003 XB. Why do you think you need to wire in a homemade regulator?

https://st-paul-harley-davidson-bue...xb9r~yt_electrical-/-ecm-/-sensors-/-lighting


It shows as the same part from '03-'10.

 

[34nineteen]

Theres nothing wrong with re-covering them, especially if you want a specific material. I was just saying it's cheaper to buy those seats. Be sure to use a 'Marine' rated vinyl for outdoor UV protection and mold resistance. It's a bit more money, unless you like re-covering your seats every year

https://st-paul-harley-davidson-bue...q=yr_2007~mk_buell~md_firebolt-xb12r~yt_seats

I used to have an extra passenger seat from my CR. I think I gave it away for $10 or something.

 

[charlevoixboy]

I read somewhere that the XB's like to eat speed sensors because they get fed 12v instead of 5v, and it was fixed in the later model years. Apparently an updated sensor had a regular built in. If that's not as popular as I gathered then it's good news and I'll skip the regulator! Haha

I got both seats recovered today. Stopped by the fabric store and broke out the sewing machine when I got home. Used the old covers as patterns and made up some new ones. Definitely not going to win any awards, but they look pretty good. I went with a grippy, black vinyl that's UV rated/waterproof. Pretty much the same material you'd get with a newer bike seat.

 

[charlevoixboy]

 

[TPEHAK]

Hey, I have same floor in my room!