How to remove your xbr motor

[squidbuellie]

I have seen a lot of members asking how to remove their motors in the last few months.
So since I had some extra time I am going to do a dyi with pictures on how to remove your firebolt motor.
All in all it should only take you 1 to 1 1/2 hours from beginning to end.

Remove seat and battery

Remove the airbox

Remove the tank vent line

Remove the airbox base plate

Push the head breathers lines and velocity stack through the base plate then remove the air intake sensor

Remove the coil wire

Remove the O2 sensor

Remove the head temp switch

Take a screwdriver or needle nose pliers to remove the wire harness plug

Take apart the throttle housing and disconnect the throttle cables from the throttle tube

I just slide the throttle tube back on

Remove the throttle cables off of the throttle body with bent nose pliers

Remove the top motor mount

Remove the clutch cable from the clutch pirch

 

[squidbuellie]

Remove the left side scoop

Remove the torques that holds the clutch cable to the front motor mount

Remove the bolts to the cross brace

Remove the bolts from the oil cooler

Remove the right side scoop

Remove the bolt that holds the cross brace

Remove the right side rider set

Remove the belt cover

Remove the bottom motor mount

Cut the zip ties that hold the wire together

Remove the oil sending light wire

 

[squidbuellie]

Spread the wires apart

Then disconnect all the wires "except" this one

Then use a 12mm wrench to remove the nut off the starter

Then if you have big hands like me then reach under the right side and disconnect the tps sensor and the fuel injectors

The bike that I'm using as a demo is a 2003 so it has the kickstand kill switch. So you have to cut a zip tie and feed the wire from the left side of the bike over to the right side

Remove the rear brake line holder

Remove the rear brake caliper

 

[iman501]

Dude, YOU ARE THE MAN!!!!!!!

Not that i need to remove mine, but I know this will help tons of people, and I may require it one day!

 

[thrstrmech]

I did my engine removal almost exactly like pictured, took an 1-1/2 to do jumping back and forth through the manual, also using pics that were posted when I had asked prior to doing it.

thanks a mil squid for that and others for your guidance

^+1[up]

 

[squidbuellie]

Zip tie the caliper to the rear passenger pegs. I like to put the two bolts back into the caliper

Stick a jack under the muffler (stock) if you do not have a stock pipe you will have to remove your pipe and stick the jack under the motor. Raise the jack up just enough to support the motor

Remove the nut from the bottom of the shock. Do Not Remove the bolt.

Break loose the top shock bolt. Do No Remove

Remove the bottom motor mount

Now here is a little tricky part, you want to raise or lower your jack under to take the pressure off of the rear shock

Then you should be able to remove the top shock bolt with ease and with the top bolt out the shock should look like this

Then slide the bottom bolt out of the shock

Then remove the fan

Remove the harness clip with a screwdriver or needle nose pliers

Swing the tranny vent line out of the way

Disconnect the fuel line and zip tie a bag on it

Remove the front motor bolt

Put the top bolt back into the shock to hold it in place

I do this by myself, but it would be easier if you have help. Hold the bars strait with your left hand and with your right arm lift the tail up, to we're you can see the top of the head

Then feed or make sure the tranny vent line is not hung up on anything

 

[squidbuellie]

Then make sure the clutch cable is clear

Then wheel barrow the frame over the motor and you should have something like this

When all is said and done you should have one or two zip lock bags with some nuts and bolts, and some big take off parts

I also forgot to add the you want to zip tie the rider set to the right rear passenger rider set and if you have the stock muffler you want to remove the chin fairing.

Hopefully this will help some of you guys out, and as i said before it should only take you about one to one and a half hours to do it. There is no real big differences between the xb9 and xb12 except the exhaust valve cable.

Later on this week ill try to do a quick write up, on how to put it all back together again.

 

[Josh662234]

What a guy. thanks a million Alex.

 

[squidbuellie]

Here are some side notes....
If you are just doing top end work, you can bye pass removing the oil cooler.
But if your going to do a lot of motor work it's much easier to break the oil cooler loose so your not fighting it while its rocking back and forth.

Also drain the oil first if your going to crack the cases. You will also want to break loose the axle bolt for the rear rim.
With the motor out you can lower the jack down a bit and pull the rear axle and the belt will be real loose.
I like to leave the rear swing arm on to help balance the motor.

And if you don't have a motorcycle rear stand. You can do it on the kickstand, but you will need help to wheel barrow the motor because you are not lifting the frame strait up and down.

Good luck....

: I forgot to add if you still have the charcoal canister you will have a vacuum line on the right side of the thottle body that you will have to disconnect.

Also here is how the motor sits

 

[nikfleisch]

Rep!

Thanks for the writeup, sticky?



:already done...

 

[LoneWolf 03XB9S]

This is going down soon as I get the bike out of storage. Marked for later reference. Thanks Squid!

 

[GAXB9R]

Thats pretty cool. Thanks squid.

 

[osinieks]

Nice tutorial! Thank You!
It seems to me I am going to do the same this winter.

('04 xb9sx with only 7k miles on odo, but it is eating oil almost more than gasoline)

 

[Orests]

It helped me a lot. Thanks !!!

 

[Silverrider]

Thats pretty kool. Thanks squid.

 

[francog77]

best how-to writeup to date

 

[Provy]

I am starting this tomorrow. Thanks for this writeup!

 

[Nebulus]

Major major thanks for this write-up! It is thorough and easy to follow. Word to the wise if you're doing this by yourself; have your passenger footpegs on before you wheelbarrow the top off! Or put the passenger riderset back on after doing the rear motor mount. Setting the tail down on something without them is a hassle.

 

[RedXb12]

Tackling this next we for a broken exhaust bolt. Thank you

 

[Silverrider]

Tackling this next we for a broken exhaust bolt. Thank you

You might try this if you have access. https://www.ebay.com/itm/Harley-Bue...h=item20ceeb5c7f:g:MfIAAOxy69JTDHcd:rk:2:pf:0