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Buell Enthusiast
16 Posts
Discussion Starter · #1 ·
This is a placeholder, as I'll post pics once I have more time to access my laptop and give updates.

This build is for a friend of mine a few states away. He shipped me his 2003 Buell XB9R Firebolt that was all stock except the race muffler, tune, and some rider drop pegs. This is more a performance build than anything, but there is a surprising amount of custom finishing and non-motor upgrades being done. This is a no holds-barred 90" conversion (984cc to 1475cc). I'll get into the details later, but the main goal is to build a bike with so much torque that it turns your underwear brown with the flick of a wrist. The stock bike puts out 70-75 RWHP and 65-70 FT/LBS, whereas the expected output after the extensive work is 125-130 RWHP and 100-110 FT/LBS. I know those numbers pale in comparison to many of the in liners around here, but the this is an air cooled pushrod V-Twin that will have 80% of its torque just over idle, and the bike has a 53" wheelbase.

I tore this bike apart months ago, and had many parts shipped out, shipped back, custom made, coated, etc. Tomorrow I'll be cutting the valve seats, squish band, and decking, and then assembling the motor and claying the pistons to make sure I have no clearance issues. Then, this weekend, I will start the reassembly, though I still have a few other changes to complete.

Buell Enthusiast
16 Posts
Discussion Starter · #2 ·
Sorry, I know I'm months behind, but between my 5 month old daughter and taking care of my dad, just haven't had much time. So a few embed photos running vid, and a link to my Imgur album will have to work for now.

when I first got it, right after the original kickstand broke in my driveway

What it looks like now so far

the ugly XB12 header is just installed for dyno tuning since it has 2 extra bungs. I'll install the ceramic header once the bike is tuned.

album link

Here's a list of the mods involved

-Bored cases
-08 XB12 crank pro plugged and balanced by Darkhorse
-07 oil pump
-bronze manganese oil pump drive gear
-NRHS CAT4 .590 lift cams modified for XB use
-S&S lifters and cylinder studs
-DK Rocker Lockers (bronze inserts to quiet rocker arm shafts)
-Axtell/NRHS 90" kit with 15* reverse dome pistons
-Smith Bros chromoly pushrods
-883 head cores with 4 new valve seats, porting and other mods by me
-AV&V 1.980" intake, 1.610" exhaust 7mm stem valves, AV&V manganese guides, S&S 650 beehive springs
-XB12 manifold ported and modified by me
-60 lb/hr injectors
-08 XB12 primary gearing
-Energy One clutch pack with Barnett +25% diaphragm spring
-easy clutch leverage extender
-XB12 header and Buell Race Muffler ceramic coated, header interior flow coated
-57 psi fuel regulator, new filter and screen
-1125R forks and trees, top tree modded for risers
-Rox offset risers with Renthal FatBar
-Strada 7 billet levers with carbon fiber inserts
-Strada 7 bar ends
-Lighting clutch cable
-Ulysses throttle cables
-ZTL2 front brake caliper and MC
-billet hidden rear caliper bracket with Brembo P32 2 piston caliper
-Spiegler front and rear brake lines, orange with blue fittings
-powdercoated wheels, dark red-orange (to match the decals) with metal flake
-04 pulleys powdercoated and CNC cut by Free Spirits
-Falcon SPC drive belt
-Free Spirits pulley cover
-Free Spirits belt tensioner
-Braking front and rear rotors
-2010 LED taillight
-Ballistic 12 cell Lithium battery
-American Sport Bike left and right carbon fiber air scoops
-Knight design drop pegs
-billet timing cover
-polished clutch and chain inspection covers
-gloss black powdercoated primary cover

I'm sure I'm forgetting stuff, and there's still more to come.

Timing and fueling still need a lot of work, but I did get it running for some heat cycles.
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