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Buell · Pushrod four-stroke twin, dry sump, separate gearbox oil, belt drive

Lightning XB9S (983 cc)

Library entry covers 2003-2010

26 factory 45 guideline

Published source

Buell 2004 XB9S Service Manual, Table 1-1 Regular Service Intervals p.1-6 (ManualsLib 1044005 page 55)

Factory service manual. Covers 2004 Buell Lightning (XB9S) service manual.

71 items for a 2009 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead valve, pushrods, adjustable tappets
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Toothed belt
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2009 Buell Lightning XB9S (983 cc)

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

Every 1,600 km or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 5,000 km or 12 months

7 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 6,500 km or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 8,000 km or 12 months

3 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Replace oil filter

Engine

Guideline
Inspect drive belt, pulleys and tension

Final drive

Guideline

Every 8,000 km or 2 years

1 item

Inspect front and rear brake calipers and master cylinders for leaks

Brakes

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Row text: every 5,000 miles (8,000 km) or two years. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.

Every 8,000 km

18 items

Change engine oil and filter

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): R at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Check engine idle speed

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Check operation of all electrical equipment and switches

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Check rear belt and idler pulley

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi. Also R at 25,000 mi; R at 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Clean oil cooler fins

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): X at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Road test

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): X at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Inspect air cleaner, service as required

Fuel and air

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 45,000 mi, 50,000 mi. Also R at 20,000 mi; R at 40,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Adjust clutch and clutch cable

Primary and gearbox

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): A at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Adjust primary chain

Final drive

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): A at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Change transmission/primary chaincase lube and clean drain plug

Final drive

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): RI at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Inspect motorcycle: front and rear brake lines, oil lines, front forks, rear shock, exhaust system and mounting

Front end

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): X at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Steering head bearing resistance test

Front end

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): X at 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Check brake fluid reservoir levels and condition

Brakes

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Inspect brake pads and rotors for wear

Brakes

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Inspect oil lines and brake system for leaks

Brakes

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Lubricate front brake hand lever, throttle and clutch control cables (and hand lever), sidestand pivot, and rear brake pedal bushing (if applicable)

Brakes

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): IL at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Check front and rear tire pressure and inspect tread

Wheels and tires

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Adjust throttle cables

Controls and cables

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): A at 1,000 mi, 5,000 mi, 10,000 mi, 15,000 mi, 20,000 mi, 25,000 mi, 30,000 mi, 35,000 mi, 40,000 mi, 45,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.

Every 9,500 km or 12 months

6 items

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 13,000 km or 2 years

1 item

Check and adjust valve clearances

Engine

Guideline

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 16,000 km

5 items

Replace spark plugs

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): R at 10,000 mi, 20,000 mi, 30,000 mi, 40,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Zero throttle position sensor (TPS)

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): A at 1,000 mi, 10,000 mi, 20,000 mi, 30,000 mi, 40,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Check ignition timing

Ignition and electrics

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): I at 10,000 mi, 20,000 mi, 30,000 mi, 40,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Change front fork oil

Front end

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): X at 10,000 mi, 20,000 mi, 30,000 mi, 40,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.
Check tightness of all critical fasteners: hand controls, brake system, front and rear axles, triple clamps, front fork components, engine mounts, stabilizers, rear shock

Front end

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): T at 10,000 mi, 20,000 mi, 30,000 mi, 40,000 mi, 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.

Every 19,500 km or 2 years

4 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 25,500 km or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 32,000 km

1 item

Air cleaner (replace)

Fuel and air

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): R at 20,000 mi, 40,000 mi. Also I at 1,000 mi; I at 5,000 mi; I at 10,000 mi; I at 15,000 mi; I at 25,000 mi; I at 30,000 mi; I at 35,000 mi; I at 45,000 mi; I at 50,000 mi. Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.

Every 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km

1 item

Replace belt and idler pulley

Engine

Factory

Factory: Table 1-1 Regular Service Intervals (p.1-6): R at 25,000 mi, 50,000 mi. Also I at 1,000 mi; I at 5,000 mi; I at 10,000 mi; I at 15,000 mi; I at 20,000 mi; I at 30,000 mi; I at 35,000 mi; I at 40,000 mi; I at 45,000 mi. Row text: replace belt and idler pulley every 25,000 mi (40,000 km). Chart codes: I = inspect, and if necessary correct, clean or replace; R = replace or change; A = adjust; L = lubricate with specified lubricant; T = tighten to proper torque; X = perform.

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 80,500 km

1 item

Replace drive belt (wear or damage based)

Final drive

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.