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Audiowize
Posted on Wednesday, July 25, 2018 - 01:16 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

So, I browse the classifieds a lot locally, and I came across a used Buell XB Lightning a few weeks ago with a reasonably low price. I went to look at the bike, and it was really pretty trashed. Both forks leaked, the clutch cable leaked, both rocker boxes leaked, the neutral light was always on, parts were missing, the wiring was a mess, etc. What I found odd was that the bike was a 2003 XB9S, but the motor and gauge cluster were from a 1200. The bike ran beautifully and the engine sounded/looked amazing. I lowballed the seller and drove off, then he texted me a few minutes later and accepted my offer so I drove back and snagged it.

So I got the title transferred and started the disassembly last night. As I'm cursing myself for buying this thing (something I'm now getting accustomed to after buying a Firebolt whose engine had been used at Bonneville), I decided I should order up those rocker gaskets. When I went to check the date code on the engine, I was surprised to see no engine code on the motor.




Does anyone recognize this "EBRCOMPXB" engine code?
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Shoggin
Posted on Wednesday, July 25, 2018 - 02:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Any better pics of the motor? Primary cover, pushrods....

I think the engine number meaning is obvious, but good luck with registering it for the street....

Interesting project!
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Akbuell
Posted on Wednesday, July 25, 2018 - 02:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Cool, actually. Maybe Brankin can step in with some info.

Of perhaps more importance, what info is on the frame? IF the frame has a valid VIN, getting it registered might not be so bad.


Agreed, interesting project.
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Natexlh1000
Posted on Wednesday, July 25, 2018 - 02:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

What the.....

Air cooled EBR?
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Vortec57
Posted on Wednesday, July 25, 2018 - 02:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Also, am I wrong in thinking the S didn't come out until 04? Or was that just the 12 models?

Pics of the whole thing? I'd say you made a sweet score!
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Audiowize
Posted on Wednesday, July 25, 2018 - 04:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The bike is already registered and plated. In Washington state, if the title is clean, they'll take your green! You actually can't do a title transfer without them charging you for registration and handing you a plate. This is a mixed blessing I suppose.

The frame is a garden variety 2003 XB9S frame. I don't think the 12 came along until 2004.

Here's the photo from the ad. It's just blurry enough to not be intentionally misleading I guess.



Here are some of the engine:





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Audiowize
Posted on Wednesday, July 25, 2018 - 04:17 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I thought these leaks were just rocker leaks, but the motor looks oily between the head and jug, so perhaps I'll have to yank the heads.





What am I looking for in terms of push rod differences? I guess I can pull the rockers today and pop them out.
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Screamer
Posted on Thursday, July 26, 2018 - 12:41 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

There were XB engines at one of the liquidation sales, but I can't remember what they had for engine numbers. A common race package was XB9 pistons with a XB12 crank, so checking the piston dome may be misleading. Pulling a head and measuring the stroke would help determine the engine size.
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Shoggin
Posted on Thursday, July 26, 2018 - 01:16 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

!!!
Glad t was cheap!


lol: )
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Falloutnl
Posted on Thursday, July 26, 2018 - 04:21 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Makes me glad to see you're putting the effort in to save a Buell from the scrapheap. Curious to see what more you will discover.
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Audiowize
Posted on Thursday, July 26, 2018 - 10:43 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I pulled the rocker covers and saw some 2006 dates, so it looks like at least the seller knew what year the motor was.

I got all the stripped bolts out, what a miracle!



This is the kind of stuff I'm dealing with. There is exactly one ring of thread left on the oil drain plug on the swingarm, so that will become an M14 plug as soon as my tap arrives.

The wife thinks I'm going to sell off all these bits, but I think I'll order up some frame paint and look for a nice set of plastics. (I also need a fork compressor for inverted forks)
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Bottlefedbuell
Posted on Thursday, July 26, 2018 - 10:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You dont need a fork compressor for these.
Cheap small hook straps will do the job fine.
Same with the seal driver, some pieces of pvc work perfect.
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Firemanjim
Posted on Thursday, July 26, 2018 - 02:52 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

As a rule head gasket will not leak oil, none under pressure there, now exhaust they will leak, but are quite noisy!!
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Audiowize
Posted on Thursday, July 26, 2018 - 04:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Good call on the head gasket, you're totally right that the oil that does pass through there isn't going to have a lot of motivation to depart through the gasket.

Peering down through the center hole in the rocker box, there's lots of oily stain in there, so my initial thought that this is just two rocker leaks seems to be confirmed.

Gaskets on order!
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Ducbsa
Posted on Friday, July 27, 2018 - 05:14 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

http://www.badweatherbikers.com/buell/messages/327 77/153628.html?1178891937
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Phelan
Posted on Saturday, July 28, 2018 - 12:54 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

No way to know the motor size without measuring the stroke, but that is an XB12 header (1 7/8" primaries, vs 1.5" primaries on an XB9 header), and the magnesium color cam cover was OEM on XB12 models, while the black primary cover was OEM on XB9 models. The intake manifold is 04-up style. If you shine a light in the intake, the throttle plate will have numbers on it. 390 is the 45mm XB9 manifold, 3019 is the 49mm XB12 manifold. All the pieces I mentioned will interchange between the 2 sizes but the 12 manifold and header are better performing than the XB9 bits (at least in terms of peak power).
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Audiowize
Posted on Saturday, July 28, 2018 - 01:53 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I'll measure the stroke tonight and have a look at those throttle plate numbers.

I answered a Craigslist ad for a guy parting an XB12 that had been totaled out in a front end collision (the front rim was toast!). He had a nice 2008 XB-12 engine sitting there with the ECU and wiring harness, so perhaps this racing motor should get mounted to my wall and saved for later?
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Ducbsa
Posted on Saturday, July 28, 2018 - 05:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

2008's are nice.
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Phelan
Posted on Monday, July 30, 2018 - 08:59 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Besides just the motor, ECM, and wiring harness for an 08 motor swap, you will need

06-10 swingarm and 08-10 oil lines (or custom lines for your existing swingarm)

06-10 dash (output shaft is a different tooth count on 06-up than 03-05, so the speedo reading will be off otherwise)

08-10 throttle body (03-07 throttle bodies do not have the IAC valve for tool-less TPS resets)

08-10 throttle cables (old cables don't fit the later throttle body)
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Nillaice
Posted on Wednesday, August 01, 2018 - 12:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I made some 08 cables fit my 07. they were longer, so I just added a spacer.
not sure if it'd fit the other way
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Audiowize
Posted on Friday, August 03, 2018 - 12:33 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

OK, I confirmed that the stroke is XB12 length, not XB9, so that's a step in the right direction. Here's a photo of the push-rods:



The butterfly plate is also stamped 3019.

I took off the timing cover and looked for the second breather, but it's not there, so this isn't a 3.6 (The stroke was too long anyway). I sure wish I knew who built this and what they had in mind. I'm not sure I should be tearing it down any more than it already is.

Tomorrow I'll be off to pick up the 2008 motor, so this engine will either go up for sale or go into my 2003 XB9R.
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Audiowize
Posted on Monday, August 13, 2018 - 05:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well, I just dumped a $500+ order on Lance for my missing bits. The 2008 motor I got looks pretty good, with the exception of a little bit of rust around the intake valves. I'll take my chances I guess!

This morning I dropped off the frame, swingarm, and metal bits and the blasted to get them all stripped down. I'm going to do a 2K satin black on the frame and swingarm along with a wrinkle black powder coat for everything else.
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Audiowize
Posted on Tuesday, August 21, 2018 - 08:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Phelan, I noticed that the fuel pump wasn't on your list of items, but the part numbers are different...
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Hughlysses
Posted on Saturday, August 25, 2018 - 03:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I made some 08 cables fit my 07. they were longer, so I just added a spacer.
not sure if it'd fit the other way


Are you sure they were 08 cables?

The 08-up cables have a 90 degree bend on the throttle body end that the earlier cables don't. I had to order new throttle cables when I did the 09 engine swap into my 07 Uly.
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Audiowize
Posted on Sunday, August 26, 2018 - 01:09 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)




Slow progress, but still progress!

Apparently my media blaster had a water leak in his shop, so I'm twiddling my thumbs a little bit waiting for the metal bits to get back.

I noticed that there's an evap canister on this thing. Can I just plug the nipple on the throttle body and route the tank breather down like the 2003?
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Audiowize
Posted on Tuesday, August 28, 2018 - 06:35 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Parts are back from the media blaster.

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Audiowize
Posted on Wednesday, August 29, 2018 - 07:57 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)




I'm very happy with the Eastwood 2K rat rod black. I decided to forgo the primer to let the blasted texture pop a little bit rather than going for the super smooth finish.
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Audiowize
Posted on Friday, August 31, 2018 - 01:14 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Making slow progress...

Where does that "upper wire guide" go?

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Audiowize
Posted on Friday, August 31, 2018 - 01:17 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Does anyone know what that plug is for on the bottom left corner of the above photo? It comes off the front of the wiring harness and is a 2 wire plug. It doesn't look like it's supposed to go into the headlight housing, but there isn't a whole lot close by for it to plug into.

I have another mystery plug in the tail as well (not the ECM port) that I'll have to get a picture of.
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Audiowize
Posted on Saturday, September 01, 2018 - 05:30 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ugh, the mystery cable looks to be for the sidestand switch. Rather than cutting it off, I will order up a plug for it and short it out that way.





The gauge cluster was missing one of its mounting posts, so I found the equivalent part and the epoxy is drying.

A bunch of the grommets were missing. I couldn't find an exact replacement, but I did find one that will work if I use a few rubber washers with it.
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