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2006 BUELL LIGHTNING MODELS SERVICE MANUAL Part Number 99490-06Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendices


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HOSE AND WIRE ROUTING

D.1

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2006 Buell Lightning: Appendix D

Figure D-1. Front and Rear Brake Systems, Right Side View

D-1


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2006 Buell Lightning: Appendix D Figure D-2. Rear Brake Systems, Top View


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2006 Buell Lightning: Appendix D

Figure D-3. Rear Brake Systems, Left Side View

D-3


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2006 Buell Lightning: Appendix D Carbon canister

Figure D-4.

Evaporative Emissions Control, California Models, Top View


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2

3

1

4

2006 Buell Lightning: Appendix D

1. 2.

To induction module From induction module (California)

3. 4.

From fuel tank (California) From fuel tank to atmosphere (49 state)

Figure D-5. Evaporative Emissions Control, California and 49 State Models, Left Side View

D-5


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2006 Buell Lightning: Appendix D

1 4

2

3

1. 2.

To active intake solenoid (Japan only) Intake air temperature sensor (IAT)

3. 4.

Fuel pump Active intake to ECM (Japan only)

Figure D-6. Wiring Harness, Left Side View


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1 2 3

2006 Buell Lightning: Appendix D

1. 2.

Fuel injector (2) Throttle position sensor (TPS)

4

3. 4.

Intake air temperature (IAT) sensor Oxygen (O2) sensor

Figure D-7. Wiring Harness, Top View

D-7


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2006 Buell Lightning: Appendix D

3 4

5 2 1 6 7

1. 2. 3. 4. 5. 6. 7. Figure D-8. Wiring Harness, Right Side View

Speedometer sensor Cable, starter to battery positive Solenoid Transmission vent line Voltage regulator Switch, oil pressure Cam position sensor


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2006 Buell Lightning: Appendix D

1

5 3

1. 2. 3.

Vent line Feed oil line Return oil line

2

4. 5.

4

Feed oil line from the oil pump to the oil cooler Return oil line from the oil cooler to the oil filter housing

Figure D-9. Oil Lines, Right Side View

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2006 Buell Lightning: Appendix D

3 1

2

1.

Vent line

2.

Feed oil line Figure D-10. Oil Lines, Bottom View

3.

Return oil line


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Exhaust valve actuator

2006 Buell Lightning: Appendix D

Muffler valve Figure D-11. Clutch Cable and Exhaust Valve Actuator (1200 only), Right Side View

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2006 Buell Lightning: Appendix D

Exhaust valve actuator

Cable, seat lock

Muffler valve

Figure D-12. Clutch, Throttle, Seat Release Cables and Exhaust Valve Actuator (1200 only), Left Side View


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Cable, seat lock

Clips into functional airbox cover.

TPS adjuster

2006 Buell Lightning: Appendix D

EVA mounted on top of functional airbox cover.

Figure D-13. Clutch, Throttle, Seat Release Cables and Exhaust Valve Actuator, Top View

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NOTES

D-14

2006 Buell Lightning: Appendix D


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ACTIVE INTAKE SYSTEM (JAPANESE MODELS ONLY) E.1 GENERAL Active Intake System (Japanese Models Only) The active intake system utilizes a solenoid in the airbox which is connected to the throttle valve via a cable. The throttle valve is automatically closed by the solenoid under certain conditions to reduce engine noise. A code 22 will set if the ECM detects that the output for the active intake control is not in agreement with the feedback circuit (minimum TP sensor voltage when actuated).

VERIFY SETTINGS 1.

Prior to verifying the active intake system, check the throttle position sensor (TPS) zero and adjust if necessary. See 1.19 THROTTLE POSITION SENSOR (TPS).

2.

Leave Digital Technician attached to vehicle.

3.

In Digital Technician, go to Active Intake test screen.

4.

Rotate throttle grip to wide open throttle (WOT).

5.

Likely causes for a code 22 are:

a.

Check that when the throttle plate reaches WOT, TPS should read above 82°.

b.

If not, see WOT CHECK listed below.

While holding the throttle wide open, activate the active intake tab on Digital Technician.

Mechanical fault in the active intake solenoid, throttle valve, or cable.

a.

Verify that the TPS setting is between 10.4-10.9 degrees.

Electrical fault in the solenoid circuit.

b.

If settings are not correct proceed to cable adjustment procedure.

Electrical fault in the throttle position sensor circuit.

When TPS reading is not between 10.4-10.9 when activated.

Diagnostic Notes The reference numbers below correlate with the circled numbers on the Code 22 flow charts. Using TEST CONNECTOR KIT (Part No. HD-41404), attach Brown pin probe and patch cord to [179] (1,2).

WOT CHECK 1.

Remove cosmetic intake cover assembly and functional air cleaner cover. See 2.37 INTAKE COVER ASSEMBLY and 1.14 AIR CLEANER FILTER.

2.

While holding the throttle grip to the WOT position, verify that the throttle plate is fully open.

If the throttle plate does not fully open, see CABLE ADJUSTMENT this section.

2006 Buell Lightning: Appendix E

E-1


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CABLE ADJUSTMENT 1.

Remove cosmetic intake cover assembly and functional air cleaner cover. See 2.37 INTAKE COVER ASSEMBLY and 1.14 AIR CLEANER FILTER.

2.

See Figure E-1. Inspect for proper retraction freeplay in solenoid shaft: a.

b.

While slowly rolling off the throttle you should be able to move the solenoid shaft slightly inward until the shaft bottoms out. This slight travel will be the retraction freeplay.

NOTE This freeplay is necessary for the solenoid to properly function. Freeplay should be 1/32 in. (0.79 mm) or greater.

Open the throttle to the WOT position, push solenoid shaft (1) inward to the fully retracted position.

c.

If you have no travel in the shaft, adjust cable housing (4) away from the solenoid bracket (3) until freeplay is achieved.

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2

4 1 3

1. 2.

Solenoid shaft Cable adjusting and jam nuts

3. 4.

Solenoid bracket Cable housing

Figure E-1. Checking for Freeplay in the Solenoid Shaft in the Fully Retracted Position

E-2

2006 Buell Lightning: Appendix E


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c.

See Figure E-2. Inspect for proper extension freeplay in solenoid shaft: a.

Open the throttle to the WOT position.

b.

Pull solenoid shaft (1) outward to the fully extended position.

4.

NOTE You should be able to move the solenoid shaft slightly outward until the shaft is fully extended. This slight travel will be the freeplay which should be 1/32 in. (0.79 mm) or greater.

If you have no travel in the shaft, loosen jam nuts (2) and adjust cable housing (4) towards the solenoid bracket (3) until freeplay is achieved.

See VERIFY SETTINGS. Once freeplay has been set, it will be necessary to verify settings and adjustments again.

If values are not between 10.4-10.9 degrees, see Throttle Stop Screw in this section.

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2

4 1 3

1. 2.

Solenoid shaft Cable adjusting and jam nuts

3. 4.

Solenoid bracket Cable housing

Figure E-2. Checking for Freeplay in the Solenoid Shaft in the Fully Extended Position

2006 Buell Lightning: Appendix E

E-3


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Throttle Stop Screw 1.

Remove cosmetic intake cover assembly and functional air cleaner cover. See 2.37 INTAKE COVER ASSEMBLY and 1.14 AIR CLEANER FILTER. 2. Hold throttle to wide open position and use cable strap to free hands. NOTE It is necessary to pull velocity stack out of the way to access set screw. 3.

Activate Active Intake System using DIGITAL TECHNICIAN. Adjust stop screw, while reading the TPS on Digital Technician, until setting is between the range of 10.4 to 10.9.

4.

a.

If the reading is below 10.4, adjust screw clockwise.

b.

If the reading is above 10.9, adjust screw counterclockwise.

5.

Reconfirm the TPS setting. Repeat process if needed.

6.

Adjust active intake cable assembly. See CABLE ADJUSTMENT.

7.

Verify active intake TPS settings.

8.

Install cosmetic intake cover assembly and functional air cleaner cover. See 2.37 INTAKE COVER ASSEMBLY and 1.14 AIR CLEANER FILTER.

10925

1

1 10924

2

1.

Cable stop screw

2.

Active cable wheel

Figure E-3. Active Intake Cable Stop Screw

E-4

2006 Buell Lightning: Appendix E


1

1

2

2

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[178B]

J2

[179B] [10A]

J4

2 2 [179A]

1 [164A] J3

1 [11A] J1

ECM

Control Signal

GY/O

W/GY

[178A]

Active Intake Solenoid

Figure E-4. Active Intake System

2006 Buell Lightning: Appendix E

E-5


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Code 22 Test (Page 1 of 2)

Is the Active Intake System cable pinched or binding? Is the solenoid stuck?

YES

NO

Repair as needed.

Remove solenoid connector [178A] and inspect connections. Are all connections tight and free of corrosion?

NO

YES

Clean and repair connections.

Disconnect active solenoid connector [178A] at solenoid. Measure voltage at pin 2 with key ON and Run/Stop switch on. Is battery voltage present?

NO

Disconnect active solenoid connector [179B] at ECM. Measure resistance at pin 2 to chassis ground. Resistance less than 10,000 ohms?

YES

Measure voltage at [178A] Pin Battery voltage present?

YES

Repair short to ground in W/GY wire.

YES

NO

Measure resistance between connector [178A] pin 2 and [179B] pin 2. (W/GY wire) Continuity present?

NO

Repair short to voltage in GY/O wire.

Measure resistance between connector [178A] pin 1 and [179B] pin 1. Continuity present?

NO

YES

Repair open in W/GY wire.

Go to page 2 of 2

YES NO

Repair open in GY/O wire.

Page 2 of 2

DIAGNOSTIC NOTE If DTC is historic, wiggle harness while performing measurements in chart to locate intermittents.

E-6

2006 Buell Lightning: Appendix E


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Code 22 Test (Page 2 of 2)

Measure resistance from active intake solenoid pin 1 to pin 2 [178B] (use HD 41404 brown pins). Continuity should be present, approximately less than 4 ohms, nominal 2.4 ohms.

YES

NO

Connect battery voltage to [178B] pin 2 of active intake solenoid. (Use HD 41404 brown pin and patch cable). Hold throttle wide open. Observe throttle plate and connect solenoid pin 1 to ground. Does solenoid attempt to pull throttle almost closed?

Replace solenoid.

YES

NO Replace solenoid.

Hold throttle wide open. Energize active intake solenoid. Does throttle close to an angle less than 11 degrees?

YES

Replace ECM.

NO

See CABLE ADJUSTMENT in this section.

2006 Buell Lightning: Appendix E

E-7


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REMOVAL

INSTALLATION NOTE

NOTE

If solenoid bracket needs to be replaced, remove the baseplate assembly, turn it over and remove the three fasteners securing the bracket to the baseplate.

It solenoid bracket was removed, reinstall using the three fasteners and tighten to 48-60 in-lbs (5.4-6.7 Nm).

1.

1.

See Figure E-5. Disconnect electrical connector [178] (1).

2.

Hold solenoid shaft by flat spot provided and break cable connector (6) loose.

3.

Unthread cable connector and disconnect cable from solenoid (8).

4.

Loosen jam nut (5) and disconnect active cable (2) from cable bracket (4).

See Figure E-5. When installing baseplate assembly (10) see 4.44 AIR CLEANER ASSEMBLY. NOTE

When installing the backing plate it is important to ensure that the active cable remains in the tower on the cable wheel on the throttle body. If the cable comes out the cable will not work properly and will not be able to be adjusted. NOTES â—?

When installing baseplate be sure to feed the electrical connector (1) through hole in baseplate first and then insert active cable and then grommet.

Follow next step only is solenoid is to be replaced.

â—?

Follow next step only if solenoid was removed.

5.

Loosen pinch fastener on solenoid bracket (9).

2.

6.

Remove the two fasteners at the front on the solenoid bracket (9) and slide solenoid (8) out of bracket.

Install solenoid (8) into bracket (9) and tighten pinch fastener to 48-60 in-lbs (5.4-6.7 Nm) and bracket to solenoid fasteners to 20-24 in lbs (2.3-2.7 Nm).

3.

Install active cable (2) into bracket (4) and leave jam nut (5) loose until the setting can be verified.

NOTE

NOTE When removing baseplate it will be necessary to feed the electrical connector and active cable and grommets through the baseplate.

4.

Connect active cable (2) to solenoid shaft and tighten cable connector (6) to 20-24 in lbs (2.3-2.7 Nm).

5.

Connect electrical connector [178].

7.

Remove baseplate (10). See 4.44 AIR CLEANER ASSEMBLY.

6.

See CABLE ADJUSTMENT and verify active cable setting.

8.

See Figure E-3. If the active cable needs to be replaced disconnect from cable wheel (2).

7.

Tighten jam nuts to 48-60 in-lbs (5.4-6.7 Nm).

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2

4 3

5

6

8

1

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

Electrical connector [178] Active intake cable Cable adjusting nut Cable bracket Active cable jam nut

Cable connector Fasteners (2), bracket to solenoid Active intake solenoid Solenoid bracket Air cleaner baseplate assembly

Figure E-5. Disconnecting Active Intake System

E-8

2006 Buell Lightning: Appendix E

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MAINTENANCE Table Of Contents

SUBJECT

PAGE NO.

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Brake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 Suspension Damping Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 Throttle Cable and Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 Interactive Exhaust Cable (XB12 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-5 1-6 1-9 1-12 1-15 1-23 1-24 1-27 1-31 1-33 1-38 1-39 1-41 1-43 1-44 1-46 1-48 1-50 1-51 1-52

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2006 BUELL LIGHTNING Service Repair Manual  
2006 BUELL LIGHTNING Service Repair Manual  
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