2008 Lightning Models Parts Catalog

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GENERAL INFORMATION

THIS IS NOT AN ASSEMBLY MANUAL AND SHOULD NOT BE USED AS SUCH.

About this Manual

This Parts Catalog has been prepared to make it easier for you to order parts for your motorcycles. The numbers shown in the illustrations correspond to the numbers in the "INDEX NO." column in the parts lists. Consult the illustrations when ordering parts to make sure that you receive all the required parts. The number in parentheses following the part description is the quantity needed for complete assembly. If there is no number in parentheses, only one is used. Prices of parts in this catalog are published separately.

When ordering parts, the following instructions should be followed carefully.

Make sure to specify the correct part number for each item. The part numbers appear under the "PART NO." column in the parts lists.
Orders may be placed via your computer for all parts. Review your system documentation on placing orders electronically. All non-warranty replacement crankcase orders require return of the complete left crankcase half with vehicle identification number (VIN). All non-warranty replacement frame orders require return of the steering neck with vehicle identification number (VIN). Non-compliance will result in a fine. See non-warranty frame and crankcase policy or contact Dealer Services.
The sale or use of these parts or accessories does not grant the purchaser a license or other right under any Harley-Davidson patent.
All parts that were added for the new model year will have the entire line shaded on the parts list page. This can be used to identify any new parts that are unique to a specific model, and help distinguish new and previous model year parts.
Parts marked "RESTRICTED SALE PART" are limited edition items and can only be ordered as direct replacements.

To the best knowledge of Buell Motorcycle Company, the material contained herein is accurate as of the date this publication was approved for printing. Buell Motorcycle Company reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation.

GENERAL INFORMATION

LOOSE PARTS

The Loose Parts section is located at the back of this parts catalog. This section lists the parts which are shipped unfastened with the vehicles covered in this catalog.

HARDWARE LIST

The Hardware List is located at the back of this parts catalog. This section contains the information for each piece of hardware found in each parts list.

NEW PARTS LIST

The New Parts List is located at the back of this parts catalog. This list serves as a summary of new parts.

NUMERICAL INDEX

The Numerical Index is located at the back of this parts catalog. This index includes all part numbers used in this catalog and the page numbers of where they can be found.

COMPONENT TYPES AND INTRODUCTION DATES

The Component Types and Introduction Dates section is located at the back of this parts catalog. This section contains a list of component part numbers and year of introduction.

COMMON SERVICE PARTS

The Common Service Parts section is located at the back of this parts catalog. This section contains the most commonly ordered parts for service on vehicles covered in this catalog. These parts are ordered through the normal ordering process.

SIP (SERVICE INFORMATION PORTAL)

For the latest updates to these manuals, see the Service Information Portal.

VEHICLE IDENTIFICATION NUMBER

See Figure 1. A unique 17-digit serial, or vehicle identification number (VIN), is assigned to each motorcycle. For a description of each digit in the vehicle identification number (VIN), refer to Table 1.

For all models the full 17-digit serial, or vehicle identification number (VIN), is stamped on the right side of the frame backbone at the rear of the steering head. The vehicle identification number (VIN) is also printed on a label on the right front downtube. An abbreviated vehicle identification number (VIN) is stamped on the left side crankcase.

POSITION	DESCRIPTION	POSSIBLE VALUES
1	Market designation (WMI code)	4MZ = Buell vehicles originally manufactured for sale within the United States 5MZ = Buell vehicles originally manufactured for sale outside the United States
2	Motorcycle type code	AX=Firebolt^® DX=Ulysses^™ JX=Lightning^® Long KP=Blast^® KX=Lightning^® CityX SX=Lightning^® WX=Lightning^® Scg XX=Lightning^® Super TT
3	Engine type	01=492cc 02=984cc 03=1203cc
4	Market configuration	A=Australia B=Brazil L=California N=Canada D=Domestic E=England R=Europe F=France J=Japan
5	V.I.N. check digit	Can be 0-9 or X
6	Model year	8=2008
7	Assembly plant	3=East Troy, WI U.S.A.
8	Model	0=Blast (08) 2=XB9SX (08) 3=XB12R (08) 4=XB12S (08) 5=XB12Scg (08) 6=XB12Ss (08) 7=XB12X (08) 8=XB12STT (08)
9	Sequential number (last five digits)	Varies

Index No.	Part No.	Description	Model(s)
	19286-08	ENGINE ASSEMBLY, w/o front isolator mount attached (not illustrated)	XB9SX
	19287-08	ENGINE ASSEMBLY, w/o front isolator mount attached (not illustrated)	XB12S, XB12STT, XB12Scg, XB12Ss
1	16466-04A	CYLINDER, w/ piston & rings	XB12S, XB12STT, XB12Scg, XB12Ss
	22710-02A	CYLINDER, w/ piston & rings	XB9SX
2	16478-85A	SCREW, internal thread (4)	ALL
3	16480-92A	SCREW, internal thread (chrome) (4)	ALL
4	16573-83A	INSERT, cylinder stud (4)	ALL
5	16715-83	STUD, exhaust port (4)	ALL
6	16770-84E	GASKET, cylinder head (2)	ALL
7	16774-86E	GASKET, cylinder base (2)	ALL
8	16832-86C	STUD, cylinder base (8)	ALL
9	16872-07A	HEAD ASSEMBLY, front cylinder - w/ valve guides & seats	ALL
	16875-07A	HEAD ASSEMBLY, rear cylinder - w/ valve guides & seats	ALL
10	17058-02D	GASKET KIT, engine overhaul	ALL
	17059-02B	GASKET KIT, top overhaul	ALL
11	18094-02A	COLLAR/SEAL, valve stem (4)	ALL
12	18020-07	SEAT, intake valve (2)	ALL
	18011-86	SEAT, exhaust valve (2)	ALL
13	18690-02	VALVE, intake (2)	ALL
	18691-02	VALVE, exhaust (2)	ALL
14	16461-02	VALVE GUIDE, intake & exhaust (4)	ALL
15	18260-02	RETAINER, valve collar (8)	ALL
16	18245-02	SPRING, valve (4)	ALL
17	18258-02	COLLAR, valve spring - upper (4)	ALL

Part No.	Description
1028	SCREW 5/16-18 X 2-1/2 SEMS socket head, with lockpatch
1039	SCREW 5/16-18 X 2-1/2 hex flange head (Grade 8)
1044	SCREW No. 4-40 X 1/4 socket head
1751	SCREW No. 1/4-20 X 3.0 hex socket
1752	SCREW No. 1/4-20 X 1-1/8 hex socket
1753	SCREW No. 1/4-20 X 3.0 hex socket
2445	SCREW 1/4-20 X 9/16 button head
3029	SCREW No. 10-24 X 1 TORX head, with adhesive
31689-90	BOLT M4 X 0.7 X 12 hex head
3403	LOCKNUT M8-1.25 X 12mm flange (zinc)
3480A	SCREW 1/4-20 X 1-3/4 knurled head (Grade 8)
3594	SCREW 1/4-20 X 5/8 knurled head (Grade 8)
3849	SCREW 1/4-20 X 1-1/4 SEMS hex head (Grade 8)
3987	BOLT 5/16-18 X 3/4 hex head (Grade 5)
3997A	BOLT 1/4-20 X 1-1/4 socket head, with sealant (zinc)
4091	SCREW No. 10-24 X 1/2 hex head, with washer, self-tapping (zinc)
4312B	SCREW M6 X 1.0 X 14mm, SEMS flange head (stainless)
4589	SCREW 9/16-12 X 2-5/16 hex flange head
4718A	SCREW 1/4-20 X 1-1/2 knurled head, with lockpatch
4748	SCREW 3/8-16 X 1-1/8 socket head (Grade 8)
4751	SCREW 1/4-20 X 3/4 hex head, with lockpatch (Grade 8) (zinc)
4820A	SCREW 1/4-20 X 2 socket head
4824	SCREW 1/4-20 X 2 SEMS socket head
6003	WASHER 1-3/16 X 1-3/8 X 11/16
6288	WASHER 17/32 X 25/32 X 1/32
6314W	WASHER 21/64 X 9/16 X 1/8 (zinc)
6400HB	WASHER 5/16 X 13/16 X 3/32
6445	WASHER 1/2 X 2 X 0.300
6787	WASHER 7/16 X 13/16 X 5/64 flat
7080	WASHER 9/16 X 3/4 X 1/4
7804	LOCKNUT 1/2-13 X 15/32 X 7/8 self-sealing
7900	CLIP NUT 1/4-20
7916A	JAMNUT 5/8-18
879A	SCREW 5/16-18 X 3-1/2 knurled head (Grade 8)
882	SCREW 1/4-20 X 7/8 knurled head, with washer (Grade 8)
8973	WASHER 1-1/4 X 1-53/64 X 9/64
928	BOLT M5 X 0.8 X 35.2 hex head
929A	SCREW M4 X 0.7 X 11.8 flange head
943	SCREW 1/4-20 X 5/8 socket button head
A05016.8CXVB	SCREW M5 X 16 truss head with Scotch grip (black olive)
A06020.2CVB	BOLT M6 X 1 X 20 socket head (black olive)
A06020.5CVB	SCREW M6 X 1.0 X 20 flat head (black olive)
A0622.21CBL	SCREW M6-1.25 X 22mm hex flange head (black chromate)
A10065.2CVB	SCREW M10 X 1.5 X 65 socket head (black olive)
AA0404.10CSS	SCREW 1/4-20 X 1/2 TORX button head (stainless)
AA0404.11CXZB	SCREW 1/4-20 X 1/2 TORX truss head, with Scotch grip (bright zinc)
AA0404.11CZB	SCREW 1/4-20 X 1/2 TORX truss head (bright zinc)
AA0404.5CZB	SCREW 1/4-20 X 1/2 socket flat head (Grade 8)
AA0405.2CXZB	SCREW 1/4-20 X 5/8 socket head, with Scotch grip (zinc)
AA0406.11CXZB	SCREW 1/4-20 X 3/4 TORX truss head, with Scotch rip (bright zinc)
AA0406.11CZB	SCREW 1/4-20 X 3/4 TORX truss head (bright zinc)
AA0406.21CZB	SCREW 1/4-20 X 3/4 hex flange head (bright zinc)
AA0406.2CXZB	SCREW 1/4-20 X 3/4 socket head, with lockpatch (zinc)
AA0406.2CZB	SCREW 1/4-20 X 3/4 socket head (zinc)
AA0409.5CZB	SCREW 1/4-20 X 1 self-tapping with ultraseal
AA0412.11CXZB	SCREW 1/4-20 X 1.5 TORX truss head, with Scotch grip (Grade 2) (bright zinc)
AA0507.2CZB	SCREW 5/16-18 X 7/8 socket head (bright zinc)
AA0508.2CXZB	SCREW 5/16-18 X 1.0 socket head, with Scotch grip (bright zinc)
AA0508.2CZB	SCREW 5/16-18 1 socket head (bright zinc)
AA0512.2CZB	BOLT 5/16-18 X 1-1/2 socket head (Grade 8)
AA0518.2CXZB	SCREW 5/16-18 X 2-1/4 SHCS, with scotchgrip (bright zinc)
AA0520.2CXZB	SCREW 5/16-18 X 2-1/2 socket head, with Scotch grip (bright zinc)
AA0522.2CZB	SCREW 5/16-18 X 2-3/4 socket head (bright zinc)
AA0608.2CXZB	SCREW 3/8-16 X 1.0 socket head (bright zinc)
AA0608.2CZB	SCREW 3/8-16 X 1.0 socket head (zinc)
AA0609.11CXZB	SCREW 3/8-16 X 1-1/8 TORX truss head, with Scotch grip (bright zinc)
AA0615.2CZB	SCREW 3/8-16 X 1-7/8 socket head (bright zinc)
AA0620.2CZB	SCREW 3/8-16 X 2.5 socket head (bright zinc)
AA0624.1CZB	SCREW 3/8-16 X 3 hex head (bright zinc)
AA0634.2CZB	SCREW 3/8-16 X 4-1/4 socket head (zinc)
AA0636.2CZ	SCREW 3/8-16 X 4-1/2 socket head (zinc)
AA0712.2CZB	SCREW 7/16-14 X 1-1/2 socket head (bright zinc)
AN0805.5CSS	SCREW 8-32 X 5/8 socket flat countersink head (stainless)
AN0808.14CSS	SCREW No. 8-32 X 1 Phillips pan head (stainless)
AN0808.3CZB	SCREW No. 8-32 X 1 button head (bright zinc)
AN1004.21FRZB	SCREW No. 10-32 X 1/2 thread cutting
AN1004.2CZ	SCREW No. 10-24 X 1/2 socket head
AN1004.3FKZB	SCREW No. 10-32 X 1/2 socket button head, with Scotch grip
AN1005.2CZ	SCREW No. 10-24 X 5/8, socket head
AN1005.3FSS	SCREW No. 10-32 X 5/8 button head (stainless)
AN1006.2CXZB	BOLT No. 10-24 X 3/4 socket head, with Scotch grip
AN1009.2CXZB	BOLT No. 10-24 X 1-1/8 socket head, with lockpatch
AN1010.11FZB	SCREW No. 10-32 X 1-1/4 TORX truss head (bright zinc)
B0510.1BL	WASHER 5mm X 10mm flat (black chromate)
B0613.1BL	WASHER 6mm X 13mm flat (black chromate)
B0814.4BL	WASHER 8mm X 14mm external star (black chromate)
BA0308.1ZB	WASHER 3/16 X 1/2 flat (bright zinc)
BA0409.1Z	WASHER 1/4 X 9/16 standard (zinc)
BA0409.4Z	WASHER 1/4 external star
BA0409.6	WASHER 1/4 X 9/16 nylon
BA0410.3Z	WASHER 1/4 X 11/16 flat (zinc)
BA0509.6	WASHER 5/16 X 9/16 nylon
BA0511.2Z	WASHER 5/16 X 11/16 flat, hardened (zinc)
BA0613.2Z	WASHER 3/8 X 13/16 thick, hardened (zinc)
CA0018.02A8	SCREW shoulder (stainless steel)
CA0052.5AA	SCREW M5 X 25 SHCS (black zinc)
CA0053.5AA	SCREW M5 X 40 SHCS (black zinc)
D0500.1CBL	JAMNUT M5 X 10 (black chromate)
D0600.2CBL	LOCKNUT M6 X 1 (black)
D0800.4FBL	JAMNUT M8 X 1.025, nylock (black chromate)
DA0400.2CZ	LOCKNUT 1/4-28 X 20 nylock (zinc)
DA0400.3CZ	LOCKNUT 1/4-20 staked (zinc)
DA0400.8CZ	LOCKNUT 1/4-20 thin nylock
DA0500.10CZ	LOCKNUT 5/16-18 spring lock (zinc)
DA0500.11CZ	LOCKNUT 5/16-18 clear flexlock (zinc)
DA0500.12FZ	LOCKNUT 5/16-24 (zinc)
DA0500.1CZ	NUT 5/16-18 clear zinc
DA0500.2CZ	LOCKNUT 5/16-18 nylock (zinc)
DA0500.8FZ	NUT 5/16-24 thin nylock (zinc)
DA0600.11CZ	LOCKNUT 3/8-16 thin (zinc)
DA0600.12FAZB	LOCKNUT 3/8-24 flange (Grade 5)
DN1000.4FZB	JAMNUT No. 10-32 thin (Grade 12) (zinc)

Part No.	Description	Part and Model(s)
10080	CLAMP	CRANKCASE & GEARCASE: All Models
11105	O-RING	PRIMARY COVER & CHAIN TENSIONER: All Models SWINGARM - 9SX/12S/12Scg: XB9SX XB12S XB12Scg SWINGARM - 12Ss/12STT: XB12Ss XB12STT
12074	OIL SEAL	TRANSMISSION GEARS: All Models
16715-83	STUD	CYLINDER, HEAD & VALVES: All Models
16800-84A	GASKET	ROCKER ARMS, COVERS & PUSH RODS: All Models
2445	SCREW	ELECTRONIC IGNITION SYSTEM: All Models
26995-86B	SEAL	THROTTLE BODY: All Models
63858-49	GASKET	ROCKER ARMS, COVERS & PUSH RODS: All Models
65325-83A	RETAINING RING	EXHAUST SYSTEM - 9SX: XB9SX EXHAUST SYSTEM - 12S/12Scg/12Ss/12STT: XB12S XB12Scg XB12Ss XB12STT
943	SCREW	PRIMARY COVER & CHAIN TENSIONER: All Models

Part No.	Description	Part and Model(s)
37909-90	RETAINING RING	CLUTCH: All Models
37911-90	FRICTION PLATE	CLUTCH: All Models

Index No.	Part No.	Description	Model(s)
1	215	DOWEL PIN (2)	ALL
2	358	DOWEL PIN (4)	ALL
3	879A	SCREW (5)	ALL
4	1028	SCREW, w/ washer (9)	ALL
5	1044	SCREW	ALL
6	4091	SCREW (2)	ALL
7	6314W	WASHER (5)	ALL
8	8881	BEARING RACE	ALL
9	8973	WASHER, thrust	ALL
10	10080	CLAMP, hose	ALL
11	11177A	RETAINING RING	ALL
12	11289A	O-RING	ALL
13	12068	OIL SEAL	ALL
14	16899-02	STUD, tap end (2)	ALL
15	22267-07	OIL JET ASSEMBLY, complete (2)	ALL
16	24439-08	CRANKCASE SET, w/ bushings & bearings (silver)	ALL
17	24605-07	BEARING	ALL
18	24647-87	BEARING, gear shaft (blue)	ALL
	24650-87	BEARING, gear shaft (red)	ALL
	24659-87	BEARING, gear shaft (white/gray)	ALL
	24660-87	BEARING, gear shaft (green)	ALL
19	24754-75A	DOWEL PIN (2)	ALL
20	26638-00Y	GASKET, oil jet	ALL
21	26921-02	REED VALVE ASSEMBLY	ALL
22	26922-02	VALVE, reed	ALL
23	26923-02	STOP, reed valve	ALL
24	26924-02	REED BLOCK	ALL
25	29950-07	COVER, stator wires	ALL
26	32617-00Y	SCREW, self-tapping (6)	ALL
27	32850-08	SENSOR, crank position w/ 11289A, 72199-04, 74194-98	ALL
28	35114-02	RING, retaining	ALL
29	35118-03	RING, retaining	ALL
30	40254-02	SPACER, sprocket shaft	ALL
31	45830-48	PLUG	ALL
32	62352-94B	HOSE, preformed	ALL
33	63533-41A	FITTING, connector - vent	ALL
34	72199-94	CONNECTOR	ALL
35	74194-98	TERMINAL (2)	ALL
36	AA0406.2CXZB	SCREW	ALL

Index No.	Part No.	Description	Model(s)
1	943	SCREW, sems (5)	ALL
2	4820A	SCREW, sems (13)	XB9SX
	4824	SCREW, sems (black) (13)	XB12S, XB12STT, XB12Scg, XB12Ss
3	7804	LOCKNUT, chain adjustment	ALL
4	11105	O-RING	ALL
5	25349-03	COVER KIT, clutch w/ 25377-03A	ALL
6	25377-03A	GASKET, clutch cover	ALL
7	25378-02B	GASKET, primary cover	ALL
8	25380-03	COVER KIT, inspection w/ 34819-03	ALL
9	25521-06	PRIMARY COVER, w/ 40574-06 (painted black)	XB9SX
	25542-06	PRIMARY COVER, w/ 40574-06 (painted metallic)	XB12S, XB12STT, XB12Scg, XB12Ss
10	34819-03A	GASKET, inspection cover	ALL
11	37107-06	OIL SEAL, shifter shaft	ALL
12	40039-02B	ADJUSTER ASSEMBLY, chain w/ shoe, collar, plate & screw	ALL
13	40574-06	BUSHING	ALL
14	60328-98B	DRAIN PLUG KIT, w/ 11105	ALL
15	C0230.T	PLUG	ALL

Index No.	Part No.	Description	Model(s)
1	7916A	JAM NUT	ALL
2	11317	KEY, square	ALL
3	24047-00	PINION GEAR	ALL
4	25188-08	K CAM GEAR SET, w/ pinion gear	ALL
5	26332-08	SPACER, oil gear	ALL

Index No.	Part No.	Description	Model(s)
1	3987	BOLT (4)	ALL
2	6090Y	WASHER, flat (2)	ALL
3	26995-86B	SEAL, intake manifold (2)	ALL
4	27327-07	MOUNTING FLANGE, front intake (2)	ALL
	70345-84	RETAINER, harness, throttle cable bracket (not illustrated)	ALL
5	C0054.1AA	CLAMP, wire spring, 49mm	ALL
6	CA0026.02A8	SCREW (4)	ALL
7	CA0056.5A8	SCREW (2)	ALL
8	CA0057.5A8	SCREW (4)	ALL
9	CD0012.02A8	NUT	ALL
10	CF0012.5AA	O-RING	ALL
11	N0805.5AA	CLIP, throttle cable retaining	ALL
12	P0023.5AA	BRACKET, cable	ALL
13	P0025.1AAA	VELOCITY STACK, 49mm	ALL
14	P0026.1AA	FUEL INJECTOR, front	ALL
	P0027.1AA	FUEL INJECTOR, rear	ALL
15	P0028.02A8	O-RING, fuel injector inlet (4)	ALL
16	P0268.5AA	FUEL RAIL	ALL
17	P0279.5AA	SENSOR, throttle position	ALL
18	P0282.5AA	ACTUATOR, idle air control	ALL
19	P0283.5AA	CABLE WHEEL	ALL
20	P0284.5AA	GASKET, idle air control	ALL
21	P0803.5AA	THROTTLE BODY MANIFOLD, 49mm	XB12S, XB12STT, XB12Scg, XB12Ss
	P0803.4AJ	THROTTLE BODY MANIFOLD, 45mm	XB9SX
INTERNATIONAL MODELS ONLY
22	P0815.5AA	THROTTLE BODY MANIFOLD (JAPAN), 49mm	XB12S, XB12STT, XB12Scg, XB12Ss
	P0815.4AJ	THROTTLE BODY MANIFOLD (JAPAN), 45mm	XB9SX

CYLINDER, HEAD & VALVES

ROCKER ARMS, COVERS & PUSH RODS

PISTON & FLYWHEEL ASSEMBLY

CRANKCASE & GEARCASE

PRIMARY COVER & CHAIN TENSIONER

CAMSHAFTS

OIL PUMP

THROTTLE BODY

AIR CLEANER

ALTERNATOR & REGULATOR

ELECTRONIC IGNITION SYSTEM

STARTER MOTOR

TRANSMISSION GEARS

SHIFTER

CLUTCH

BELTS & SPROCKETS

FRONT BRAKE CONTROL & CALIPER

REAR BRAKE CONTROL & CALIPER - 9SX/12S/12Scg

REAR BRAKE CONTROL & CALIPER - 12Ss/12STT

FRONT WHEEL

REAR WHEEL

STEERING HEAD

FRONT FORK - 9SX/12S/12Scg/12Ss

FRONT FORK - 12STT

REAR SHOCK ABSORBER - 9SX/12S/12Scg

REAR SHOCK ABSORBER - 12Ss/12STT

FRAME - 9SX/12S/12Scg

FRAME - 9SX/12S/12Scg (CONTINUED)

FRAME - 12Ss

FRAME - 12Ss (CONTINUED)

FRAME - 12STT

FRAME - 12STT (CONTINUED)

ENGINE MOUNTS

SWINGARM - 9SX/12S/12Scg

SWINGARM - 12Ss/12STT

HANDLEBARS & HAND CONTROLS - 12S/12Scg/12Ss

HANDLEBARS & HAND CONTROLS - 9SX/12STT

REAR FENDER & BELT GUARDS - 9SX/12S/12Scg

REAR FENDER & BELT GUARDS - 12Ss/12STT

SEAT, TAIL SECTION & TRUNK - 9SX/12S/12Scg

SEAT, TAIL SECTION & TRUNK - 12Ss/12STT

INTAKE COVER, FRONT FENDER & CHIN FAIRING

DECALS

FUEL TANK & PUMP

FUEL TANK & PUMP (CONTINUED)

OIL FILTER & LINES

EXHAUST SYSTEM - 9SX

EXHAUST SYSTEM - 12S/12Scg/12Ss/12STT

BATTERY

HEADLIGHTS, HORN & FAN

TAIL LAMP & TURN SIGNALS

INSTRUMENT CLUSTER

MAIN WIRE HARNESS

MAIN WIRE HARNESS (CONTINUED)

SWITCHES, SENSORS & ELECTRICAL CONNECTORS

LABELS

CALIFORNIA EVAPORATIVE EMISSIONS COMPONENTS

JAPAN EMISSIONS COMPONENTS