Pandoras box..or throttle.

[TheJmann]

So today I rolled out my 2003 xb9s that I bought and abruptly left behind as I moved. I put less than 200 miles on it. I bought it used with 29000mi on it. I checked the oil, new rear tire, and rode it then I was gone. Fast forward 2 years here I am, got the bike in the trailer brought it home. First nice day here in NY was almost 60 today in upstate. I rolled it out of the trailer. I had a mental list of items to address from memory.
1: sluggish throttle actuation, figured cables bad or bound.
2: oil / primary/ filter change
3: replace exhaust stud on front cylinder. (I've already rotated the motor and replaced the rear's before I rode it once.)
4: figure out a intermittent stutter while crusing(50-65mph)

Oh boy...I don't know whether to be impressed, or disgusted. First while the oil was draining I pulled the throttle tube / start /KS off the handle bar. I have no idea how I never really noticed this, but my my..
https://imgur.com/gallery/STF7rNz
So new throttle cables are now on the way.

The primary oil looked like spoiled milk, the engine oil looked fair albeit some concerning metal shavings on the plug, smelled a bit like gas, and filter was on just right. 2.5qt-Drag specialties synthetic v-twin 20w-50, Napa filter-1394, and 1qt 20w-50 drag specialties v-twin synthetic in the primary.

Behind the wind screen? I found about 8 wires that are crimp connected and electrical tapped by what I assume was a young child.

The airfilter base has 2 holes where I assume the breathers used to enter which are open allowing moar power by pulling in super hot air from above the back cylinder.

The "breather" setup was using a 3/4" hose wrapped around the left side of the throttle body, PUSHING ON THE THROTTLE CABLES.

A random wire tucked in by the shock, that was cut. I traced it out to be a ground wire for the fork assy. I'm surprised it's only 18ga.

And an open port on the right side of the throttle body, maybe 1/8 tubing sized right side. No idea, haven't looked in my service manual yet.

On a brighter note. I'm glad to find out I have newer drive pulleys with the updated belt. 0500.1AAE

And after some fresh gas, a completely dead battery, and a jump pack. It fired up relatively quick.
I pulled the coil plug and cranked for about 30s before I tried to actually start it. It would stutter every 10s or so cause the jump pack would reset. The battery was flat. 0. So it was running off the jump pack.
Xb9s https://imgur.com/gallery/Oga5WCK


stuff on the way-
Replacement pegs
Replacement throttle cables
New battery
Arp exhaust studs (manifold bolt kit)

Stuff I have yet to do / have
Yzf 03 motion motionpro throttle tube- if I need it
Jims drill jig
Buelltooth tps/ troubleshoot

Stuff I'm thinking about
-the metal on my oil plug.
-custom bracket for hella 60mm hi/low lamps
-if I should get a stabilizer for my commute. 40mi each way
-maybe I should buy a newer bike. (I really enjoy working on my stuff, so I doubt it)

Anyways I'll be updating with more pictures. Like of all the other forehead smacking stuff I found. At least it came with 3 seats, and I didn't pay much for it. But, still.

 

[Cooter]

Welcome to the forum! Sounds like you have it handled, 2 years aint so bad but still very rough on fuel pumps. Lately the outlet lines have been getting pinholes and pumps are failing. Barrett on here is a great source for QUALITY rebuild kits and assemblies. Don't forget they're 20 years old!

You shouldn't need a steering stabilizer, but I love mine and it helps the falling into corners feeling with a old squared off front tire:
https://www.buellxb.com/forum/showthread.php?53843-DIY-Cheap-steering-damper

Yes plug the holes in the airbox base, yes they were for breathers.

You can check that open port in the TB (ported vacuum source for CA and some Euro models) but 99% it's plugged internally (not drilled) and doesn't need a cap. You can cap it anyway for 2¢ if it make you feel better, because why not.

Milky gas smelling oil is common for something that sat. Don't worry about that or the shavings (unless it looks like Beakers hair?) until the next oil change, which should be soon.



Theres an available Buell LED replacement lights and housing assembly that bolts on and gets good reviews.
https://www.amazon.com/KUQIQI-headl...rds=buell+xb+headlights&qid=1615431075&sr=8-2

Sure! Buy a newer bike! Buy them all!

34:19 does.:black_eyed:

 

[TheJmann]

Thanks for the welcome!
Yeah had a few beakers hair on the oil plug.. oil change after the first 250mi, then 1000. Including the primary. This fall is getting a full tear down.

I saw your dampner setup and will most likely be going that route. Great diy design!

As the headlights I will prototype mounts with my 3d printers and after I finish will be offering the mount printed in ABS. Lights+mount my cost should be under $100.

 

[Cooter]

I only contributed the locking allen to the damper design, the OP of the thread figured out the rest of it. Odd guy who eventually got banned, but he had some good ideas to share on occasion. The chinese damper is on bike #2 now and still going strong! I actually think the Ohlins I put on the EBR is wearing out, now wouldn't that be funny... (rhetorical). On the cheap damper, the fender gets pretty close but should clear on an S, I wouldn't recommend it on an Scg.

That would bet super cool of you! I'm gonna try printing ABS on my open bed printer, and I'm aware of some of the pitfalls, but have some Buell projects in PLA now:eagerness:

 

[njloco]

Welcome to the forum, sounds to me like you got your build all set up. Here in central Jersey I go through a lot of traffic commuting and the only time I feel like I needed a steering damper was going slow on small tight streets doing right and left turns but never enough to tip the desire to build Cooter's version but I am a lazy person , this was on the SS. I don't seem to have this problem on the Ully at all, if fact it seems to really like turning sharp into slow turns maybe it's the extra weight ?
I have those headlights in the link Cooter put up, while always better to make your own, I do love these headlights.

 

[34nineteen]

I have those headlights in the link Cooter put up, while always better to make your own, I do love these headlights.

I am planning on buying a set per your recommendation.

 

[njloco]

I think you will like them a lot, through the few years I've been a Bueller the only sore bone I've had when it comes to complaints were the headlights, that is not the case anymore, after you get them please let me know what you think.

 

[TheJmann]

Thanks njloco! I'll be posting pics of the headlights but that's later this year. As for the dampner I'll do without for now and install later if I desire..(I will at some point).

Can anyone verify they primary locking tool dimensions? I am going to pull the primary cover and verify torque / red loctite my flywheel nut as well. Dimensions I have are 4-1/8"L x 1"w with 30⁰ bevel opposing sides?

Also my replacement buelltooth came in, I have stored codes :
23: injector 1 short to ground/open
32: injector 2 short to ground/broken wire

These codes were in stored not current, I'm thinking it was due to running my bike off a jump pack that would reset every 10s while I had it idling to get up to temp for the earl change. Because my battery was reading literally 0, battery since be replaced.

My fuel pump is...very loud. I have had walbro 255lph and they where whiney. It's always sounded like this but I have never inquired if it's "normal". Obviously I only hear it with ignition on to get fuel pressure before starting.

Cooter, I highly suggest trying petg with your open bed. I switched to petg for majority of my printing ( 5 printers) and while it was another learning curve the **** is soo strong. All my printers besides 1 is open bed, 60c bed 240c hotend and 30% part fan and the stuff is ridiculously strong. And same cost as pla, overhangs are the only downside.

 

[Cooter]

Thanks so much for the details, I'll give it a shot!

 

[TheJmann]

No problem, message me if you have any questions on it. You don't get the toxic fumes with petg either

 

[34nineteen]

I think you will like them a lot, through the few years I've been a Bueller the only sore bone I've had when it comes to complaints were the headlights, that is not the case anymore, after you get them please let me know what you think.

NJ- check this out. I found these LED lights on eBay.

https://www.ebay.com/itm/Buell-LED-...797365?hash=item36777b35b5:g:zecAAOSwowxdfjhy

While I'm usually wary of eBay stuff, when I visited his store, he appears to be a Bueller and sells other XB specific parts as well. Theyre a little more expensive that the Amazon lights, but I like the idea of supporting someone who is putting new Buell specific product into the world.

 

[TheJmann]

NJ- check this out. I found these LED lights on eBay.

https://www.ebay.com/itm/Buell-LED-...797365?hash=item36777b35b5:g:zecAAOSwowxdfjhy

While I'm usually wary of eBay stuff, when I visited his store, he appears to be a Bueller and sells other XB specific parts as well. Theyre a little more expensive that the Amazon lights, but I like the idea of supporting someone who is putting new Buell specific product into the world.

Stuff looks nice! I would definitely buy them but want to make my own, his air box deletes look awesome!

 

[34nineteen]

Stuff looks nice! I would definitely buy them but want to make my own, his are box deletes look awesome!

I need to get one also. Cooter likes to put small bits of hardware in the recess where the actuator motor used to live on my airbox, so my bike always has constant weird rattles. :mad-new:

 

[TheJmann]

Wait the rattles are not normal?

I need to get one also. Cooter likes to put small bits of hardware in the recess where the actuator motor used to live on my airbox, so my bike always has constant weird rattles. :mad-new:[/QUOTE

I'm gonna band wagon here but ahem...don't you need a running bike to hear the rattles? According to Cooter you have like a bike ...graveyard

 

[TheJmann]

So made the locking bar today, I'm hoping to ride it this weekend for a little bit to get the oil in the primary sloshed around a bit so I can drain it. Then it's a longer list of stuff I ordered.. primary gasket kit, shifter o-ring, clutch sealing washer, intake gaskets, and torque that damn flywheel nut just because I have no idea if it was ever done. Hell the motor may be shot, but it runs for now.

 

[TheJmann]

So today I planned on changing my throttle cables, and I started with the pull cable. Got the new one routed..and low and behold I'm short. Guess what, I was sent firebolt cables ****. End to adjusting nut I measured 31.5"? I think. Oh well, another set ordered.

I figure since I have the headlight off let's swap out these turn signals with these awesome chinesium leds I ordered. I actually really like them, in the fronts they have a white lip "see pictures" like a dtr and rears have red. Not bad for like $22 on Amazon. https://photos.app.goo.gl/pRxteeZZJawgXphY6
https://photos.app.goo.gl/Y7Ey4Pz1BjDKsKcC8
Then I started to swap out the rear sets with the cheapest set I could find. $45? And they are not too shabby! I will post pics tomorrow since my phone didn't save them for some reason. I fully installed them but didn't torque anything because I want to blue loctite everything and wanted to adjust them where I wanted.

And lastly installed a uly sprocket guard because well mine was missing and I found this one on fleabay for like $18. So win. Pictures also missing will post tomorrow.

So now more waiting for parts, while I could be riding. Oh why to the lords of 2 wheels must I suffer due to my incompetence.

 

[34nineteen]

So made the locking bar today, I'm hoping to ride it this weekend for a little bit to get the oil in the primary sloshed around a bit so I can drain it. Then it's a longer list of stuff I ordered.. primary gasket kit, shifter o-ring, clutch sealing washer, intake gaskets, and torque that damn flywheel nut just because I have no idea if it was ever done. Hell the motor may be shot, but it runs for now.

What is the "clutch sealing washer"?

You will want to get the gaskets for the chain and clutch inspection covers in the primary case. The book says to replace them everytime, but I just do it when they leak. And... the shifter shaft seal was available in an early and late version. The early one was smaller, the later one was larger. I think the year split was 2006?

I wouldnt mess with the flywheel nut unless you are having issues. If it was going to let loose, it likely would have done so years ago. If you "re-torque" it, you will likely be fighting the factory red locktite, and if you happen to tighten the bolt a little further, you've just broken the locktite bond. So, if you're gonna do it, loosen, clean thoroughly, re-locktite and torque 'er down. Also, remember the torque on the flywheel nut has been increased to 240-260lb/ft.

With the fluid, I did a similar thing when I resurrected my last XB. I ran ATF in the primary to clean out any gunk and get it all in suspension before I flushed it and refilled with Formula +. Its not really a "quart out/quart in"... its more like about 28-30oz. You should have a little left over to get the fluid height correct.

I'm gonna band wagon here but ahem...don't you need a running bike to hear the rattles? According to Cooter you have like a bike ...graveyard

Touche. He's not kidding. I've had this habit lately of picking up strays. Don't do meth, just dont.

 

[TheJmann]

I meant clutch sealing o-ring. For the primary gaskets I bought this https://www.ebay.com/itm/Cometic-Ga...-/333922116649?_trksid=p2349624.m46890.l49292.

Shifter o ring from st.paul
https://st-paul-harley-davidson-bue...r-shaft-seal-l2c5?_pos=9&_sid=12076c0e0&_ss=r

Intake gaskets
https://st-paul-harley-davidson-bue...take-seals-l2c6-1?_pos=1&_sid=4ef45c2f9&_ss=r

I only planned to verify it was torqued aka visual not with a wrench. If it looks suspicious I'll pull it, chase the threads and goop the red death on it.

Some how I've managed to spend more on this bike this year than I paid for it. But rev 2 throttle, ebr left/ right controls, a used crg clutch lever, revival throttle cable kit to make a new pull cable from the firebolt cable I have, and a cute little volt meter for the dash.

Don't worry my buell hasn't seen the street in years which is sad. Some how I feel that I will start accumulating deprived misfits before long. We can support each other in our unhealthy habits

 

[TheJmann]

Here are some pics

 

[njloco]

Well don't ride anyplace next to 34's house, that is just the type of Buell he looks for and you'll never be able to escape the black hole like gravity pulling you in !

Yeah, I like the way those headlights look, just make sure whatever bulbs are in there are available.