Take The Spark Plugs Out Of A Buell Xb9r

The Buell Firebolt XB9R was a groundbreaking motorcycle when it was introduced in 2002, featuring several innovations aimed at lowering the motorcycle’s center of gravity for improved agility and handling. Buell’s new fuel-in-frame concept, as well the relocation of the oil tank into the rear swingarm, proved beneficial and would be used on successive Buell motorcycles until 2010. Unfortunately, the design of the XB9R’s massive frame made it difficult to access the pair of spark plugs powering the Harley-Davidson Sportster-derived V-twin engine. Partially disassembling the motorcycle, however, can provide enough room to remove and replace both spark plugs.

Instructions

1. Lift the rear corners of the front seat cushion to access the seat bolts. Unscrew both seat bolts, using a Torx T-27 screwdriver. Lift the rear of the seat, then pull the seat toward the rear of the motorcycle until the hooks below the seat are free from the motorcycle’s frame.

2. Unscrew the bolts from the front and the base of the dummy fuel tank cover, using a Torx T-27 screwdriver. Lift the fuel tank cover away from the motorcycle to reveal the air cleaner.

3. Unscrew the wing nuts attaching the upper air cleaner cover to the air filter, by hand. Pull the air cleaner off the air cleaner base plate, by hand. Unscrew the bolts from all four corners of the air cleaner base plate, using a Torx T-27 screwdriver. Lift the air cleaner base plate slightly and unplug the air temperature sensor connector from the bottom of the air cleaner base plate.

4. Remove the left air intake duct, located below the left frame rail, near the front fork, using a Torx T-27 screwdriver. Pull the intake duct away from the engine to reveal the front cylinder spark plug.

5. Unplug the spark plug cable from the front cylinder spark plug, by hand. Unscrew the front cylinder spark plug, using a socket wrench fitted with a 5/8-inch swiveling spark plug socket and a six-inch extension. Insert the socket from above the engine, through the gap between the front cylinder and the left frame rail.

6. Install a new spark plug, if desired, into the front cylinder. Reach under the left frame rail and screw the spark plug into place, by hand. Tighten the spark plug to 18 foot-pounds, using a torque wrench inserted between the left frame rail and the front cylinder.

7. Reach between the left frame rail and the raised air box support, then pull the spark plug cable off the rear cylinder spark plug, by hand. Insert a socket wrench fitted with a 5/8-inch flexible spark plug socket and a six-inch extension through the gap between the left frame rail and the air box support. Unscrew the rear cylinder spark plug, using the socket wrench.

8. Screw a new rear cylinder spark plug loosely into place, if desired, using a socket wrench fitted with a 5/8-inch flexible spark plug socket and a six-inch extension. Tighten the spark plug to 18 foot-pounds, using a torque wrench inserted through the left frame rail and the air box support. Push the spark plug cable onto the rear cylinder spark plug.

9. Reinstall the left air intake duct onto the motorcycle’s frame, using a Torx T-27 screwdriver. Reinstall the air cleaner base plate, using a Torx T-27 screwdriver. Push the air cleaner into place over the base plate flange, then remount the upper air cleaner cover. Screw the upper cover wing nuts into place, by hand.

10. Reinstall the dummy fuel tank cover over the air cleaner and the motorcycle’s frame. Tighten the fuel tank cover bolts, using a Torx T-27 screwdriver.

11. Slip the front seat hooks into the motorcycle’s frame. Screw the seat bolts into place, using a Torx T-27 screwdriver.