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Buell 2002 P3, Service Manual

The Buell 2002 P3 Service Manual is a comprehensive and essential resource for owners and enthusiasts. This detailed manual, available for free download from 88.208.23.73:8080, provides step-by-step instructions and crucial information on maintenance, troubleshooting, and repairs. Get your hands on the manual to ensure optimal performance and longevity of your Buell motorcycle.

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Appendix C: Metric Conversions

C-1

 

HOME

 

METRIC CONVERSIONS

C.1

 

MILLIMETERS TO INCHES

(MM X 0.03937 = INCHES)

INCHES TO MILLIMETERS

(INCHES X 25.40 = MM)

mm

in. mm

in. mm

in. mm

in. in.

mm in.

mm in.

mm in.

mm

 

.1

.2

.3

.4

.5

.6

.7

.8

.9

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

.0039

.0078

.0118

.0157

.0197

.0236

.0275

.0315

.0354

.0394

.0787

.1181

.1575

.1968

.2362

.2756

.3149

.3543

.3937

.4331

.4724

.5118

.5512

.5905

.6299

.6693

.7086

.7480

.7874

.8268

.8661

.9055

.9449

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

.9842

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.338

1.378

1.417

1.456

1.496

1.535

1.575

1.614

1.653

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.968

2.008

2.047

2.086

2.126

2.165

2.205

2.244

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

90

2.283

2.323

2.362

2.401

2.441

2.480

2.519

2.559

2.598

2.638

2.677

2.716

2.756

2.795

2.834

2.874

2.913

2.953

2.992

3.031

3.071

3.110

3.149

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.464

3.504

3.543

91

92

93

94

95

96

97

98

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

3.582

3.622

3.661

3.701

3.740

3.779

3.819

3.858

3.897

3.937

3.976

4.016

4.055

4.094

4.134

4.173

4.212

4.252

4.291

4.331

4.370

4.409

4.449

4.488

4.527

4.567

4.606

4.645

4.685

4.724

4.764

4.803

4.842

.001

.002

.003

.004

.005

.006

.007

.008

.009

.010

 

1

 

/

 

64

 

.020

.030

 

1

 

/

 

32

 

.040

.050

.060

 

1

 

/

 

16

 

.070

.080

.090

.1

 

1

 

/

 

8

 

3

 

/

 

16

 

.2

 

1

 

/

 

4

 

.3

 

5

 

/

 

16

 

3

 

/

 

8

 

.4

 

7

 

/

 

16

 

1

 

/

 

2

 

9

 

/

 

16

 

.025

.051

.076

.102

.127

.152

.178

.203

.229

.254

.397

.508

.762

.794

1.016

1.270

1.524

1.588

1.778

2.032

2.286

2.540

3.175

4.762

5.080

6.350

7.620

7.938

9.525

10.160

11.112

12.700

14.288

.6

 

5

 

/

 

8

11

 

/

 

16

 

.7

 

3

 

/

 

4

 

.8

 

13

 

/

 

16

7

 

/

 

8

 

.9

 

15

 

/

 

16

 

1

1

 

 1

 

/

 

16

 

1.1

1

 

 1

 

/

 

8

 

1

 

 3

 

/

 

16

 

1.2

1

 

 1

 

/

 

4

 

1.3

1

 

 5

 

/

 

16

 

1

 

 3

 

/

 

8

 

1.4

1

 

 7

 

/

 

16

 

1

 

 1

 

/

 

2

 

1

 

 9

 

/

 

16

 

1.6

1

 

 5

 

/

 

8

 

1

 

 11

 

/

 

16

 

1.7

1

 

 3

 

/

 

4

 

1.8

1

 

 13

 

/

 

16

 

1

 

 7

 

/

 

8

 

1.9

15.240

15.875

17.462

17.780

19.050

20.320

20.638

22.225

22.860

23.812

25.40

26.99

27.94

28.57

30.16

30.48

31.75

33.02

33.34

34.92

35.56

36.51

38.10

39.69

40.64

41.27

42.86

43.18

44.45

45.72

46.04

47.62

48.26

1

 

 15

 

/

 

16

 

2

2

 

 1

 

/

 

16

 

2.1

2

 

 1

 

/

 

8

 

2

 

 3

 

/

 

16

 

2.2

2

 

 1

 

/

 

4

 

2.3

2

 

 5

 

/

 

16

 

2

 

 3

 

/

 

8

 

2.4

2

 

 7

 

/

 

16

 

2

 

 1

 

/

 

2

 

2

 

 9

 

/

 

16

 

2.6

2

 

 5

 

/

 

8

 

2

 

 11

 

/

 

16

 

2.7

2

 

 3

 

/

 

4

 

2.8

2

 

 13

 

/

 

16

 

2

 

 7

 

/

 

8

 

2.9

2

 

 15

 

/

 

16

 

3

3

 

 1

 

/

 

16

 

3.1

3

 

 1

 

/

 

8

 

3

 

 3

 

/

 

16

 

3.2

3

 

 1

 

/

 

4

 

3.3

49.21

50.80

52.39

53.34

53.97

55.56

55.88

57.15

58.42

58.74

60.32

60.96

61.91

63.50

65.09

66.04

66.67

68.26

68.58

69.85

71.12

71.44

73.02

73.66

74.61

76.20

77.79

78.74

79.37

80.96

81.28

82.55

83.82

3

 

 5

 

/

 

16

 

3

 

 3

 

/

 

8

 

3.4

3

 

 7

 

/

 

16

 

3

 

 1

 

/

 

2

 

3

 

 9

 

/

 

16

 

3.6

3

 

 5

 

/

 

8

 

3

 

 11

 

/

 

16

 

3.7

3

 

 3

 

/

 

4

 

3.8

3

 

 13

 

/

 

16

 

3

 

 7

 

/

 

8

 

3.9

3

 

 15

 

/

 

16

 

4

4

 

 1

 

/

 

16

 

4.1

4

 

 1

 

/

 

8

 

4

 

 3

 

/

 

16

 

4.2

4

 

 1

 

/

 

4

 

4.3

4

 

 5

 

/

 

16

 

4

 

 3

 

/

 

8

 

4.4

4

 

 7

 

/

 

16

 

4

 

 1

 

/

 

2

 

4

 

 9

 

/

 

16

 

4.6

4

 

 5

 

/

 

8

 

4

 

 11

 

/

 

16

 

84.14

85.72

86.36

87.31

88.90

90.49

91.44

92.07

93.66

93.98

95.25

96.52

96.84

98.42

99.06

100.01

101.6

102.19

104.14

104.77

106.36

106.68

107.95

109.22

109.54

111.12

111.76

112.71

114.30

115.89

116.84

117.47

119.06

Summary of Contents for 2002 P3

Page 1: ...02 BUELL P3 SERVICE MANUAL Part Number 99491 02Y Section 1 Maintenance Section 2 Chassis Section 3 Engine Section 4 Fuel System Section 5 Starter Section 6 Drive Transmission Section 7 Electrical Appendix ...

Page 2: ......

Page 3: ...o B 41174 2 Replacement Pad Part No B 41177 Front Fork Holding Tool Part No B 43933 Wheel Bearing Remover Installer Use with Part No HD 44060 Part No B 43982 Sprocket Locking Tool Part No B 43983 Main Drive Gear Cross Plate Used with Part No HD 35316A Part No B 43985 Transmission Remover Installer Part No B 43987 Engine Cradle Used with HD 42310 ...

Page 4: ... 2 Part No B 43991 Fork Seal Bushing Driver Part No B 59000A Pro Level Oil Gauge Part No HD 25070 Robinair Heat Gun Part No HD 33223 1 Cylinder Compression Gauge Part No HD 33413 A Carburetor Idle Adjustment Tool Part No HD 33416 Universal Driver Handle Part No HD 33418 Universal Puller Forcing Screw ...

Page 5: ... Part No HD 34623B Piston Pin Retaining Ring Installer Remover Part No HD 34643A Shoulderless Valve Guide Seal Installer Part No HD 34723 Valve Guide Hone 8 mm Part No HD 34731 Shoulderless Valve Guide Installation Tool Part No HD 34736B Valve Spring Compressor Part No HD 34740 Driver Handle and Remover Use with Part No HD 34643A and art No HD 34731 ...

Page 6: ...ler Part No HD 35102 Wrist Pin Bushing Hone 20 mm Part No HD 35316 A Main Drive Gear Remover Installer and Main Drive Gear Bearing Installer Part No HD 35381 Belt Tension Gauge Part No HD 35457 Black Light Leak Detector Part No HD 35500A Digital Multi Meter FLUKE 23 Part No HD 35518 Internal External Retaining Ring Pliers ...

Page 7: ...db ndbno bho knsdl hlno hslnslnnsdl hlno hso bho knsdl hlno hslnslp pffb odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pklhb odlbndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho bs npond bpdk kznh odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbnd...

Page 8: ... Bushing Reamer Fixture Part No HD 39151 Shift Drum Retaining Ring Installer Part No HD 39301 A Steering Head Bearing Race Remover Part No HD 39302 Steering Head Bearing Race Installer Part No HD 39458 Sprocket Shaft Bearing Outer Race Installer Part No HD 39565 Engine Sound Probe Part No HD 39617 Inductive Amp Probe Use with Part No HD 35500A T S P O R S T E R 1 3 C C 4 0 ...

Page 9: ...Part No HD 39786 Cylinder Head Holding Fixture Part No HD 39800 Oil Filter Crusher Small Part No HD 39823 Oil Filter Crusher Large Part No HD 39847 Universal Ratcheting Tap Reamer Handle Part No HD 39932 Steel or HD 39932 CAR Carbide Intake and Exhaust Valve Guide Reamer Part No HD 39964 Reamer Lubricant Cool Tool ...

Page 10: ...69 Ultra Torch UT 100 Part No BU 44473 Tool Organizational System Part No HD 41137 Hose Clamp Pliers Part No HD 41155 VHS Video Shelf Part No HD 41183 Heat Shield Attachment Use with Part No HD 25070 Part No HD 41185 Hose Cutting Tool Part No HD 41185 1 Oil Hose Cutter Replacement Blade ...

Page 11: ...rive Gear Seal Installer Part No HD 41609 Amp Terminal Crimp Tool Part No HD 41675 Oil Pressure Sending Unit Wrench Part No HD 42310 Engine Transmission Stand Part No HD 42310 150 Drip Tray Use with Part No HD 42310 Part No HD 42320 Piston Pin Remover Installer Part No HD 42322 Piston Support Plate ...

Page 12: ...D 42774 Sprocket Shaft Seal Installer Part No HD 43646 Engine Stand 600 200 Made in USA PP 9606 0001 Part No HD 43984 Crankshaft Locking Tool Part No HD 44358 Flywheel Support Fixture Part No HD 43682 10 Drip pan Use with Part No HD 43682 or Part No HD 43646 Part No HD 44069 Timkin Snap ring remover and installer Use with Part No HD 44404 ...

Page 13: ...47 102 Part No HD 94547 102 Drive Handle Use with Part No HD 94547 101 Part No HD 94660 37B Mainshaft Locknut Wrench Use with Part No B 43982 Part No HD 94800 26A Connecting Rod Bushing Reamers and Pilots Part No HD 94803 67 Intake Camshaft Bushing Reamer Part No HD 94804 57 Rocker Arm Bushing Reamer Part No HD 94812 1 Pinion Shaft Bushing Reamer Use with Part No HD 94812 87 ...

Page 14: ... Puller Figure 3 1 Part No HD 95637 46A Wedge Attachment for Claw Puller Use with Part No HD 95635 46 Part No HD 95760 69A Bushing Bearing Puller Tool Set Set includes items 1 7 Items 8 HD 95769 69 9 HD 95770 69 and 10 HD 95771 69 are optional Part No HD 95952 33B Connecting Rod Clamping Tool Part No HD 95970 32D Piston Pin Bushing Tool Part No HD 96215 49 Small Internal Retaining Ring Pliers ...

Page 15: ...ing Compressor Part No HD 96550 36A Valve Lapping Tool Part No HD 96710 40B Crankcase Main Bearing Lapping Tool Part No HD 96718 87 Pinion Bearing Outer Race Lapping Kit Part No HD 96796 47 Valve Spring Tester Part No HD 96921 52B Oil Pressure Gauge Part No HD 96921 58 Oil Pressure Gauge Adapter Use with Part No HD 96921 52B ...

Page 16: ... 14 Appendix A Tools HOME Part No HD 97087 65B Hose Clamp Pliers Part No HD 97273 60 Camshaft Bushing Installer Part No HD 97292 61 Two Claw Puller Part No J 5586 Transmission Shaft Retaining Ring Pliers ...

Page 17: ...A 15 Appendix A Tools HOME ...

Page 18: ...ace Packard Speedometer Indicators On back of speedometer 46 2 place barrel connector Voltage Regulator Above swingarm left side 60 2 place Amp Multilock Side Stand Switch On top of swingarm cable tied to rear brake line 61 9 slot fuse block Fuse Block Under seat on right side 65 3 place Deutsch Speed Sensor Under seat to right of shock 83 3 place Amp Multilock Ignition Coil Under frame backbone a...

Page 19: ...n con nector must be installed with the arrow pointing toward the external latch See Figure B 2 If the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its fully installed position REMOVING INSTALLING PINS 1 See Figure B 1 Remove ...

Page 20: ...een crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact NOTE Inspect the quality of the core and insulati...

Page 21: ... terminal Figure B 7 a With the flat edge against the terminal insert the pick Snap On TT600 3 into the cavity until it stops b Pivot the end of the pick away from the terminal to release the tang c Gently tug on wire to pull terminal from chamber Do not tug on the wire until the tang is released or the terminal will be difficult to remove A click is heard if the tang is engaged but then inadverte...

Page 22: ...on always being the top of the connector 1 From the secondary lock side of the connector insert the terminal into its respective numbered chamber until it snaps in place For proper fit the slot in the terminal must face the tang in the chamber a If installing socket terminals see Figure B 6 b If installing pin terminals see Figure B 7 2 Gently tug on wire end to verify that the terminal is locked ...

Page 23: ... insulation Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact 6 See Figure B 8 Ins...

Page 24: ...AGE F TOGND FROM START RELAY BK 2 INTEG RATED ELEC TRONI CIGNI TION MODULE 131 120 121 1 2 3 4 6 5 TAIL STOP 128 30A A B C D KEY SWITC H R GN B K 86 30 85 87 87A RELAY 33 TN W BK BK W SIDESTAND SWITC H 1 2 65 60 123 86 30 85 87 87A SYSTEM RELAY FUSE BLOC K TOP VIEW 61 O LIGHTS 15A KEY SWITC H SYSTEM 15A DIODE 1 DIODE 2 SPARE 15A IGNI T ION SPARE ACC ESSORY MASTER C B RIGHT FRON T LAMP HEADLAMP HIG...

Page 25: ...WITCH 15A LIGHTS 61 TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 4 3 2 1 CLUTCH SWITCH 95 16 Y 16 GY 16 R 2 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B 6A RATING 6A RATING 16 R B C D A F E D C B A ON OFF PARK LOCK F E D C B A KEY SWITCH LOGIC TO BATT NEG MAIN CHASSIS GROUND 4 3 2 1 MASTER C B 123 START RELAY 87A 87 85 30 86 30A 128 START RELAY FROM TO GND BATTERY R BE BK 2 1 COLOR CODE B...

Page 26: ...arging R 1 R 1 BK BK R BK 3 BK 3 R 46 30A 128 BK 2 BK BK COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLOW LT LIGHT DIODE NO CONNECTION PIN CONNECTOR SOCKET CONNECTOR SPLICE CONNECTION CONNECTOR CODE a0278x7x ...

Page 27: ...D R BK BK R R BK KEY SWITCH R 2 D C B A 24 O Y BK GN HORN GY HORN POWER 122 BK HORN 9 2 8 7 6 5 4 3 1 R 7 5A 7 5A 7 5A 15A MASTER C B ACCESSORY SPARE IGNITION 15A SPARE DIODE 2 DIODE 1 15A SYSTEM KEY SWITCH 15A LIGHTS O R B 1 RELAY SYSTEM 87A 87 85 30 86 R R 1 BK R 1 R B 1 GN R 30A 128 TN Y COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLO...

Page 28: ... 3 2 1 171 7 16 R 2 D A 7 5A 7 5A 7 5A 15A Y GY TO BATT NEG MAIN CHASSIS GROUND FLASHER MASTER C B ACCESSORY SPARE IGNITION 15A SPARE DIODE 2 DIODE 1 15A SYSTEM KEY SWITCH 15A LIGHTS 61 TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 33 K B GN R KEY SWITCH D C B A 30A 128 5 6 4 3 2 1 R Y O 39 38 24 9 2 8 7 6 5 4 3 1 9 2 8 7 6 5 4 3 1 O 16 Y 16 GY 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B ...

Page 29: ...RY MASTER C B 1 2 3 4 MAIN C HASSIS G ROUND TOBATT NEG G Y 1 2 3 4 5 6 AUTO ENRIC H THROTTLE POSITION SENSOR K B LBE Y 15A 7 5A 7 5A 7 5A 95 CL UTC H SWITC H 10 83 PK IGNMODULE GN BK W R W BK W BK R W BK PK W BK V W K B BK TN Y V O FROM 3 R R R B 1 R1 R1 R G Y G Y V O O W V W V K B S14 22 TN Y R B 1 R R O SWITC H NEUTRAL 131 TN R 2 R 2 R BK BK TN GN BK R BK R IGNPOWER BE R BK1 TN TN W R 2 TN GN R ...

Page 30: ...67 4 606 4 645 4 685 4 724 4 764 4 803 4 842 001 002 003 004 005 006 007 008 009 010 1 64 020 030 1 32 040 050 060 1 16 070 080 090 1 1 8 3 16 2 1 4 3 5 16 3 8 4 7 16 1 2 9 16 025 051 076 102 127 152 178 203 229 254 397 508 762 794 1 016 1 270 1 524 1 588 1 778 2 032 2 286 2 540 3 175 4 762 5 080 6 350 7 620 7 938 9 525 10 160 11 112 12 700 14 288 6 5 8 11 16 7 3 4 8 13 16 7 8 9 15 16 1 1 1 16 1 1...

Page 31: ...AE 5 STEEL 120 000 PSI MEDIUM CARBON HEAT TREAT 14 22 10 19 33 54 78 114 154 257 382 587 SAE 7 STEEL 133 000 PSI MEDIUM CARBON ALLOY 13 25 44 71 110 154 215 360 570 840 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SOCKET SET SCREW 212 000 PSI HIGH CARBON QUENCHED TEMPERED 9 16 30 70 1...

Page 32: ...C 3 Appendix C Metric Conversions HOME ...

Page 33: ...mary Fluid 1 17 1 11 Drive Belt and Rear Sprocket 1 19 1 12 Primary Chain 1 22 1 13 Rear Shock Absorber 1 23 1 14 Front Fork Oil 1 24 1 15 Steering Head Bearings 1 26 1 16 Spark Plug 1 27 1 17 Air Cleaner 1 28 1 18 Throttle Cables 1 30 1 19 Ignition Timing and Idle Speed Adjustment 1 31 1 20 Fuel Supply Valve and Filter Strainer 1 33 1 21 Starter Interlock and Electrical Switches 1 35 1 22 Critica...

Page 34: ...ys the most important consideration when per forming any job Be sure you have a complete understanding of the task to be performed Use common sense Use the proper tools Protect yourself and bystanders with approved eye protection14 Don t just do the job do the job safely Removing Parts Always consider the weight of a part when lifting Use a hoist whenever necessary Do not lift heavy parts by hand ...

Page 35: ...h the mating part Always use the proper tools and fixtures for removing and installing bearings Bearings do not usually need to be removed Remove bear ings only if necessary Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with the bushing bore Use a bea...

Page 36: ...ion on a wrench handle If possible always pull on a wrench handle and adjust your stance to prevent a fall if something lets go Never cock a wrench Never use a hammer on any wrench other than a STRIK ING FACE wrench Discard any wrench with broken or battered points Never use a pipe wrench to bend raise or lift a pipe Pliers cutters prybars Plastic or vinyl covered pliers handles are not intended t...

Page 37: ...se hand sockets on power or impact wrenches Select the right size socket for the job Never cock any wrench or socket Select only impact sockets for use with air or electric impact wrenches Replace sockets showing cracks or wear Keep sockets clean Always use approved eye protection when using power or impact sockets Storage Units Don t open more than one loaded drawer at a time Close each drawer be...

Page 38: ...bles and hand lever and side stand L L L L L Lubricate and adjust steering head bearings X Check operation and throttle control I I I I I I I I I I I Inspect fuel valve lines and fittings for leaks I I I I I I I I I I I Clean fuel tank filter screen X Check operation of all electrical equipment switches including starter interlock I I I I I I I I I I I Check battery and clean connections I I I I I...

Page 39: ...r vice versa refer to the following Fluid ounces U S x 29 574 milliliters Pints U S x 0 473 liters Quarts U S x 0 946 liters Gallons U S x 3 785 liters Milliliters x 0 0338 fluid ounces U S Liters x 2 114 pints U S Liters x 1 057 quarts U S Liters x 0 264 gallons U S BRAKE FLUID 11WARNING 1WARNING D O T 4 brake fluid can cause irritation of eyes and skin and may be harmful if swallowed If large am...

Page 40: ...proper usage Follow instructions provided with decals for proper application Prep Sol will not affect molded in color panels If you are unsure of how to use this product see your Buell dealer Washing To wash molded in color panels follow the instructions below Rinse surface with water Wash with Harley Wash or Harley Sun Wash Rinse surface thoroughly with water Dry with a clean chamois or soft dry ...

Page 41: ...1 8 2002 Buell P3 Maintenance HOME NOTES ...

Page 42: ...y on the battery pad termi nal side facing up CAUTION Connect the cables to the correct battery terminals or damage to the motorcycle electrical system will occur 11WARNING 1WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious in...

Page 43: ...ower mark on dip stick To do so may result in equipment damage and or equipment malfunction CAUTION Do not overfill oil tank Doing so may result in oil carry over to the air cleaner equipment damage and or equip ment malfunction CAUTION Do not switch engine oil brands indiscriminately Some oils interact chemically when mixed Use of inferior oils or non detergent oils can damage the engine The moto...

Page 44: ...o not overtighten 11 Place two drain hoses back on the hose fixture Install drain plugs to drain hoses and secure plugs with spring clamps 12 See Figure 1 2 See Table 1 3 Remove dipstick and refill with approximately 1 5 qts 1 419 5 ml recommended oil at filler hole 13 Install dipstick and operate motorcycle for 10 minutes to reach normal operating temperature Check oil level again hot check and a...

Page 45: ...rs Check rear brake pedal operation Before every ride At the 1000 mile 1600 km service interval At every 5000 mile 8000 km service interval there after Lubricate the front brake hand lever Every 5 000 miles 8 000 km FLUID LEVEL See Figure 1 5 With motorcycle in a level position check that brake fluid is between the upper and lower marks on front and rear reservoirs Add D O T 4 BRAKE FLUID if neces...

Page 46: ...er cylinder cover Bring fluid level to within 0 125 in 3 2 mm of molded boss inside front master cylinder b Remove cap and gasket from rear master cylinder reservoir Bring fluid level to between upper and lower marks on reservoir 3 Depress release and then hold brake lever pedal to build up hydraulic pressure 4 Open bleeder valve metric about 1 2 turn counterclock wise brake fluid will flow from b...

Page 47: ... Always replace brake pads in pairs BRAKE ROTORS 11WARNING 1WARNING Do not allow brake fluid bearing grease or other lubri cants to contact brake rotor or reduced braking ability may occur which could result in death or serious injury Check front and rear brake rotors for minimum thickness At the 1000 mile 1600 km service interval At every scheduled service interval thereafter 1 Measure rotor thic...

Page 48: ...hereafter WHEEL BEARINGS The wheel bearings are sealed units no greasing or mainte nance is required Replace when worn Excessive play or roughness indicates worn bearings that require replacement Check wheel bearings Whenever wheel is removed tire change fork oil change 1 4 Tire Specifications Pressures P3 Tires SOLO RIDING LOADED TO GVWR Front Dunlop 100 80 16 50s K330 28 psi 193 kPa 32 psi 220 k...

Page 49: ...ing screw 6 clockwise 1 4 turn Install lock plate 5 and spring 4 on adjusting screw flats If hex on lockplate does not align with recess in outer ramp rotate adjusting screw clockwise until it aligns 7 Squeeze clutch hand lever to maximum limit three times This sets the ball and ramp mechanism Pull outer cable conduit and at the same time adjust cable adjuster to provide 0 0625 0 125 in 1 6 3 2 mm...

Page 50: ...ght position 6 See Figure 1 14 Install clutch inspection cover using three TORX screws with washers Tighten in a crosswise pattern to 7 9 ft lbs 9 5 12 2 Nm 7 Install left footpeg support bracket See 2 21 FOOT PEGS AND FOOTPEG SUPPORT BRACKETS 8 Connect negative battery cable to battery See 1 4 BAT TERY 9 Install seat See 2 28 SEAT CHANGING TRANSMISSION FLUID 1 Raise rear wheel off floor using REA...

Page 51: ...sengagement clutch drag and or difficulty in finding neutral at engine idle 8 See Figure 1 15 Add SPORT TRANS FLUID Part No 98854 96 quart size Part No 98855 96 gallon size as required until fluid level is even with bottom of clutch dia phragm spring 9 See Figure 1 14 Install clutch inspection cover using three TORX screws with washers Tighten in a crosswise pattern to 7 9 ft lbs 9 5 12 2 Nm 10 In...

Page 52: ...ed maximum allowable deflection 11WARNING 1WARNING Check alignment of the rear wheel and or brake calipers when servicing motorcycle A misaligned rear wheel and or brake caliper could cause the rear brake disc to bind resulting in loss of control and death or serious injury Rear Sprocket 1 See Figure 1 17 Inspect each tooth of rear sprocket for a Major tooth damage b Gouges caused by hard objects ...

Page 53: ... CONDITION REQUIRED ACTION 1 Internal tooth cracks hairline OK to run but monitor condition 2 External tooth cracks Replace belt 3 Missing teeth Replace belt 4 Chipping not serious OK to run but monitor condition 5 Fuzzy edge cord OK to run but monitor condition 6 Hook wear Replace belt 7 Stone damage Replace belt if damage is on the edge 8 Bevel wear outboard edge only OK to run but monitor condi...

Page 54: ...two TORX screws and washers See 2 23 FENDERS 17 Install front sprocket cover with three TORX screws and washers See 2 22 SPROCKET COVER 18 Position rear sprocket on rear wheel with mounting holes aligned 11WARNING 1WARNING Use only new P N BA0511 2Z hardened washers between sprocket cover and sprocket Failure to use hardened washers could cause sprocket to fail Drive sprocket fail ure could lead t...

Page 55: ...d dis carded at the first adjustment interval 1 See Figure 1 22 Back off locknut and chain limiting screw Remove spacer IMPORTANT NOTE Be certain to use Inch Pound Wrench Chain adjuster shoe can be damaged by excessive force 2 See Figure 1 23 Tighten chain limiting screw to 24 in lbs 3 Back off chain limiting screw 3 4 turn 4 1 2 flats 4 Hold chain limiting screw while tightening jam nut Figure 1 ...

Page 56: ...hock eye bushings for deterioration At every 10 000 mile 16 000 km service interval NOTE Rear shock absorber contains no user serviceable parts Replace the shock absorber if it fails Figure 1 24 Rear Shock Absorber Assembly 1 Bolt 2 Damper Bushing 3 Damper 4 Nut 5 Stopper Ring 6 Spring Seat 7 Spring 8 Spring Seat Stopper a0015xSx 1 2 3 4 1 2 4 5 6 7 8 ...

Page 57: ...GE 1 Remove front forks See 2 17 FRONT FORK 2 See Figure 1 25 Clamp the fork in a vise with front fork holding tool part no B 4177 3 See Figure 1 26 Remove slider tube cap 4 See Figure 1 27 Push down on the B spring seat O ring included and remove the stopper ring and spring seat Figure 1 25 Clamping the Fork Figure 1 26 Slider Tube Cap Figure 1 27 B Spring Seat 3767 3768 3769 ...

Page 58: ...ing seat and spring collar 9 Coat a new O ring with fork oil or sealing grease 10 Install new O ring onto spring seat 11 See Figure 1 30 Push down on spring seat past groove to install stopper ring Stopper ring will lock into groove when installed correctly 12 See Figure 1 31 Install slider tube cap 13 Install front forks See 2 17 FRONT FORK Figure 1 28 Removing Sub Assembly Figure 1 29 Pumping Fo...

Page 59: ...h clutch cable to handlebar NOTE Check that clutch and throttle cables do not bind when mea suring bearing resistance ADJUSTMENT 1 Detach clutch cable at handlebar 2 Remove seat and fuel tank See 4 2 FUEL TANK COVER FUEL TANK 3 Attach lifting straps to frame backbone behind steering neck Raise front wheel off floor using a floor hoist and lifting straps 4 Turn front wheel to full right lock 5 See ...

Page 60: ...elec trodes and is caused by an air fuel mixture that is too lean a hot running engine valves not seating or improper ignition timing The glassy deposit on the spark plug is a conductor when hot and may cause high speed misfiring A plug with eroded electrodes heavy deposits or a cracked insulator must be replaced d A plug with a white yellow tan or rusty brown pow dery deposit indicates balanced c...

Page 61: ...oved detach clean air inlet hose from middle fitting on 3 way connector 10 Remove gasket from inboard side of air box Discard gasket CLEANING AND IINSPECTION 1 Thoroughly clean air cleaner cover and backplate 2 Replace the filter element if damaged or if filter media cannot be adequately cleaned 11WARNING 1WARNING Do not use gasoline or solvents to clean the filter ele ment Volatile or flammable c...

Page 62: ...ck positions Alternately tighten screws to 18 22 in lbs 20 2 5 Nm 6 Slide spacer onto longer allen head screw gold if removed Apply a small dab of Loctite Medium Strength Threadlocker 243 blue to threads of screw and install into remaining hole in venturi ring 2 o clock position Tighten screw to 18 22 in lbs 20 2 5 Nm 7 Squeeze wings on spring clamp with pliers and push free end of clean air inlet...

Page 63: ... adjuster lock 3 on each adjuster 3 Turn adjusters 4 in direction which will shorten cable housings to minimum length 4 Point front wheel straight ahead Twist throttle control grip to fully open position hold in position 5 Turn adjuster 4 on throttle control cable 1 until throttle cam stop touches carburetor stop plate Tighten adjuster lock on throttle control cable 1 adjuster 4 release throttle c...

Page 64: ...at the rpm listed Failure to do so may result in running engine with too much spark advance and may cause extreme engine knock and engine failure 6 See Figure 1 40 Timing light will flash each time an igni tion system spark occurs Aim timing light into timing inspection hole The advance timing mark two dots should be centered in timing inspection hole If this is the case ignition timing is properl...

Page 65: ...ecause there are variations in individ ual components it is possible for a properly warmed up engine to idle at 2000 RPM 2 See Figure 1 42 The ignition coil cable is located on the left side of the bike behind the fuel supply valve Place HAND HELD TACHOMETER SNAP On Part No ONO SE 1100 on ignition coil cable 3 Press the tachometer button to obtain a reading for the current RPM 4 See Figure 1 43 Se...

Page 66: ...ttery negative terminal 3 Drain fuel tank as follows a Rotate handle on the fuel supply valve to the fully vertical position to shut the gasoline supply to the carburetor OFF See A of Figure 1 44 11WARNING 1WARNING Some gasoline will drain from the outlet hose when dis connected from the fuel valve Thoroughly wipe up any spilt fuel immediately Dispose of rags in a suitable man ner Gasoline is extr...

Page 67: ...e on flange of fuel valve assembly 3 Insert fuel valve assembly into fuel tank bore and install two allen head screws Alternately tighten screws to 6 10 in lbs 0 7 1 1 Nm 4 Push hose onto outlet fitting at side of fuel valve Turn slotted screw to tighten band clamp 5 Verify that handle of fuel supply valve is in the OFF posi tion and fill the fuel tank 6 Rotate handle of fuel supply valve to ON an...

Page 68: ...ee conditions must exist to allow operation of the vehicle Clutch disengaged lever pulled in must be done whenever starting motorcycle Transmission in Neutral Sidestand retracted If the motorcycle starts and operates without any of the three conditions being met see 7 11 STARTER IGNITION INTER LOCK for troubleshooting procedures TESTING SWITCHES Check the following electric switches for proper ope...

Page 69: ... 3 7 Nm Handlebar Fasteners 10 12 ft lbs 14 16 Nm Brake Banjo Bolts 16 20 ft lbs 22 27 Nm Brake Caliper Mounting Bolts Front 18 22 ft lbs 24 30 Nm Rear Large 18 22 ft lbs 24 30 Nm Rear Small 14 5 18 ft lbs 20 24 Nm Caliper Pin 11 14 5 ft lbs 15 20 Nm Front and Rear Rotor TORX Screws 24 27 ft lbs 33 37 Nm Front and Rear Axle Nuts Front 38 42 ft lbs 52 57 Nm Rear 48 52 ft lbs 65 71 Nm Front Fork Upp...

Page 70: ...lways unplug or turn off battery charger before con necting or disconnecting charger clamps at battery Con necting or disconnecting clamps with charger on could cause a spark and a possible battery explosion A bat tery explosion may rupture the battery case and spray sulfuric acid onto the surrounding area and personnel which could result in death or serious injury Store battery out of reach of ch...

Page 71: ...correctly 6 Ignition coil not functioning 7 Engine oil too heavy winter operation 8 Ignition not timed properly 9 Fuel tank filler cap vent plugged or carburetor fuel line closed off restricting fuel flow 10 Water or dirt in fuel system and carburetor 11 Enrichener valve inoperative 12 Air leak at intake manifold 13 Valves sticking Starts But Runs Irregularly or Misses 1 Spark plug in bad conditio...

Page 72: ... to air cleaner ELECTRICAL SYSTEM Alternator Does Not Charge 1 Regulator rectifier module not functioning 2 Rectifier not grounded 3 Engine ground wire loose or broken 4 Loose or broken wires in charging circuit 5 Stator not functioning 6 Rotor not functioning Alternator Charge Rate Is Below Normal 1 Regulator rectifier module not functioning 2 Stator not functioning 3 Rotor not functioning 4 Weak...

Page 73: ...front nut to 38 42 ft lbs 51 5 56 94 Nm Tighten rear nut to 48 52 ft lbs 65 70 Nm 3 Excessive wheel hub bearing play 4 Rear wheel out of alignment with frame and front wheel 5 Rims and tires out of true sideways tire runout should not be more than 5 64 in 2 0 mm 6 Rims and tires out of round or eccentric with hub tire runout should not be more than 3 32 in 2 4 mm 7 Irregular or peaked front tire t...

Page 74: ...Rear Brake Master Cylinder 2 28 2 14 Rear Brake Caliper 2 31 2 15 Rear Shock Absorber 2 34 2 16 Throttle Control 2 35 2 17 Front Fork 2 37 2 18 Fork Stem And Bracket Assembly 2 50 2 19 Swingarm 2 52 2 20 Exhaust System 2 53 2 21 Footpeg Support Bracket 2 55 2 22 Sprocket Cover 2 56 2 23 Fenders 2 57 2 24 Lower Belt Guard 2 58 2 25 Tail Section And Rear Frame Assembly 2 59 2 26 Windscreen 2 61 2 27...

Page 75: ......

Page 76: ...VWR 780 353 GAWR Front 280 127 GAWR Rear 500 226 Load Capacity 400 181 CAPACITIES U S Metric Fuel Tank Total including reserve Reserve 2 8 gallons 0 55 gallons 10 60 liters 2 08 liters Oil Tank with filter 2 0 quarts 1 89 liters Transmission Primary 32 0 ounces 946 35 ml Front Fork each wet capacity 9 2 ounces 272 08 ml TIRE AND POSITION SOLO RIDING LOADED TO GVWR Front Dunlop 100 80 16 50s K330 2...

Page 77: ...d lever pivot bolt 4 13 in lbs 0 5 1 5 Nm LOCTITE ANTI SEIZE Page 2 21 Front brake line clamp screw 3 5 ft lbs 4 7 Nm Page 2 26 Front brake switch screw 7 13 in lbs 0 8 1 5 Nm Page 2 21 Front fender mounting screws 27 30 in lbs 3 1 3 4 Nm Page 2 55 Front isolator mount bolt See NOTES See NOTES Torque to 20 ft lbs 27 1 Nm turn bolt clockwise an additional 63 67 Page 2 64 Front muffler bolts 22 25 f...

Page 78: ...3 blue to last few threads metric Page 2 28 Rear muffler strap bolts 22 25 ft lbs 30 34 Nm Page 2 52 Rear shock top and bottom bolt 35 40 ft lbs 47 54 Nm Page 2 33 Steering head cap nut pinch screw 7 10 ft lbs 10 14 Nm Page 2 49 Steering head cap nut 28 32 ft lbs 38 43 Nm Page 2 49 Steering head lower triple tree clamp screws 22 29 ft lbs 30 39 Nm Page 2 49 Steering head upper triple tree clamp sc...

Page 79: ...he sidewall Rim size and contour are marked on the rim s exterior surface Example MT 2 5 x 16 0 DOT MT designates the rim contour 2 5 is the width of the bead seat measured in inches 16 0 is the normal diameter of the rim in inches mea sured at the bead seat diameter DOT means that the rim meets Department of Transpor tation Federal Motor Vehicle Safety Standards See the table below Table 2 1 Tire...

Page 80: ...n Number when ordering parts or making inquiries about your Buell motorcycle Figure 2 1 Vehicle Identification Numbers V I N Sample V I N as it appears on the steering head 4MZKP13C723500015 Sample abbreviated V I N as it appears on the left side crankcase KP132500015 13 World 58 California Manufacturer Buell Motorcycle Company Engine 500001 520000 World 520001 525000 CA Type Designation Buell Bla...

Page 81: ...o 38 42 ft lbs 52 57 Nm Tighten rear axle nut metric to 48 52 ft lbs 65 71 Nm Excessive side play or radial up and down play in wheel hubs Replace wheel hub bearings Alignment of rear wheel in frame or with front wheel Repair swingarm as described under 2 19 SWINGARM Rims and tires out of true sideways should not be more than 0 080 in 2 03 mm Replace rims See 2 9 TIRES Rims and tires out of round ...

Page 82: ...ome cases small punctures in the tread area may be repaired from within the demounted tire by your Buell dealer Speed should not exceed 50 mph 80 km h for the first 24 hours after repair and the repaired tire should NEVER be used over 80 mph 128 km h In emergency situations if a temporary repair is made ride slowly with as light of a load as possible until the tire is permanently repaired or repla...

Page 83: ...sen front axle nut 4 6 Loosen pinch screw 2 7 Remove front axle nut spacer and washer Pull front axle out of wheel hub while supporting front wheel DISASSEMBLY 1 See Figure 2 6 Remove five bolts 10 and washers 11 to detach front brake rotor 12 from wheel hub Discard washers 2 Remove tire See 2 9 TIRES CLEANING AND INSPECTION 1 Thoroughly clean all parts in solvent 2 Inspect all parts for damage or...

Page 84: ...sembly a0161a2x 1 4 2 9 12 10 3 5 6 8 7 1 Nut metric 2 Left Axle Spacer 3 Wheel Bearing 4 Wheel 5 Valve Stem 6 Wheel Weight 7 Axle Spacer Center 8 Wheel Bearing 9 Front Axle 10 Brake Rotor Bolt 5 11 Brake Rotor Washer 5 12 Front Brake Rotor 13 Washer 11 1 13 ...

Page 85: ...e 2 9 TIRES 3 Verify that wheel and tire are true See 2 8 CHECKING CAST RIM RUNOUT 4 Balance tire See 2 9 TIRES Adjustment INSTALLATION 1 Install front axle a Position wheel between forks with brake rotor on gearcase side of motor b With pinch screw metric loose insert threaded end of axle through right side fork c Push axle through fork and wheel hub until axle begins to emerge from left side of ...

Page 86: ...NG AND INSPECTION 1 Thoroughly clean all parts in solvent 2 Inspect all parts for damage or excessive wear 3 Inspect brake rotor a Measure rotor thickness Replace if less than 4 5 mm See 2 14 REAR BRAKE CALIPER b Check rotor surface Replace if warped or badly scored 4 Inspect tire See 2 9 TIRES ASSEMBLY 11WARNING 1WARNING Do not allow brake fluid bearing grease or other lubri cants to contact brak...

Page 87: ...or is thoroughly clean b Apply LOCTITE THREADLOCKER 272 red to threads of each of the five T40 TORX screws 8 c Install rotor 9 on wheel hub Tighten TORX screws in criss cross pattern to 24 27 ft lbs 33 37 Nm Figure 2 9 Rear Wheel Assembly 2 4 7 5 3 9 6 12 1 8 10 1 Nut metric 2 Left Axle Spacer 3 Wheel Bearing Left side 4 Wheel 5 Axle Spacer Center 6 Wheel Bearing 7 Rear Axle 8 Brake Rotor Screw 5 ...

Page 88: ...rotor 3 Slide axle through washer swing arm carrier left side spacer and wheel assembly a See Figure 2 11 Hold right side spacer in place b Insert axle through right side spacer and swingarm c Install flat washer lockwasher and axle nut 4 Place screwdriver or rod through axle hole and torque rear axle nut to 48 52 ft lbs 65 71 Nm 5 Slide belt on sprocket teeth by rotating wheel to walk belt onto t...

Page 89: ...te lubricant to threads of forc ing screw 1 to prolong service life and ensure smooth operation b Install nut 2 washer 3 and Nice bearing 4 on screw Insert assembly through hole in bridge 5 c Drop ball bearing inside collet 6 Fasten collet and ball bearing to forcing screw 1 3 Hold end of forcing screw 1 and turn collet 6 to expand edges of collet 4 See Figure 2 14 When expanded collet has gripped...

Page 90: ...n no longer be turned Remove tool 3 Install spacer sleeve inside wheel hub 4 Reverse tool and install opposite side bearing PART NO SPECIALTY TOOL B 43933 See Figure 2 17 Wheel bearing installer remover Figure 2 15 Installation Tool Support Plate Figure 2 16 Installing Bearing a0202x2x a0203x2x 1 2 3 5 6 4 1 Threaded Rod 2 Nut 3 Washer 4 Nice Bearing 5 Pilot 6 Wheel Bearing Figure 2 17 Wheel Beari...

Page 91: ...fication shown in Table 2 3 Rim Radial Runout 1 See Figure 2 19 Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification shown in Table 2 3 Table 2 3 Wheel Runout WHEEL TYPE MAXIMUM LATERAL RUNOUT MAXIMUM RADIAL RUNOUT C...

Page 92: ...EEL 2 Rear wheel only Remove rear sprocket See 2 6 REAR WHEEL Disassembly 3 Deflate tire 4 See Figure 2 20 Loosen both tire beads from rim flange 11WARNING 1WARNING Do not use excessive force when starting bead over rim Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury 5 If a bead breaker machine is not available attach RIM PROTECTOR...

Page 93: ...bead onto rim with tire tools working toward valve in both directions 11WARNING 1WARNING Do not inflate over 40 psi 276 kPa to seat the beads Inflating the tire beyond 40 psi 276 kPa to seat the beads can cause the tire rim assembly to burst with force which could result in death or serious injury 6 Apply air to stem to seat beads on rim It may be neces sary to use a TIRE BEAD EXPANDER Part No HD ...

Page 94: ...ce is 1 0 oz 28 g total weight applied to the front wheel 2 0 oz 56 g total weight applied to the rear wheel Wheels should be balanced to within 1 4 oz 7 g at 60 MPH 97 KM H See Figure 2 25 Use only WHEEL WEIGHTS Part No 43692 94Y which have special self adhesive backings Apply WHEEL WEIGHTS to the flat surface of the wheel rim 1 Make sure that area of application is completely clean dry and free ...

Page 95: ...jo bolt seating surfaces will leak when reassembled Prevent damage to seating surfaces by carefully removing brake line components 3 See Figure 2 27 Remove banjo bolt 6 metric and two banjo washers 4 to disconnect brake line 5 from mas ter cylinder Discard banjo washers 4 Unplug both terminals to detach brake lamp switch NOTE The individual parts of the brake lamp switch are not service able Repla...

Page 96: ...sult in improper brake operation which could result in death or serious injury 1 Clean all parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contaminate with mineral oil or other solvents Wipe dry with a clean lint free cloth Blow out drilled passages and bore with a clean air supply Do not use a wire or similar instrument to clean drilled pas sages in bottom of reservoir 2 Carefully insp...

Page 97: ... lbs 9 14 Nm 11WARNING 1WARNING Use only new black banjo washers See Parts Catalog for Part No with D O T 4 brake fluid Earlier silver banjo washers are not compatible with D O T 4 fluid and will not seal properly over time Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury CAUTION To avoid leakage ensure that banjo washer...

Page 98: ...rews 3 Tighten to 9 13 in lbs 1 0 1 5 Nm 10 Bleed brake system See 1 6 BRAKE SYSTEM MAIN TENANCE 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper brake lamp operation could result in death or serious injury 11 Turn ignition key switch to IGN Apply brake hand lever to test brake lamp operation T...

Page 99: ...er DISASSEMBLY 1 See Figure 2 38 Use BRAKE CALIPER PISTON REMOVER Part No B 42887 to pull the two pistons from caliper bores 2 See Figure 2 39 Remove piston outer seals 4 and inner seals 2 from their respective grooves in caliper Discard seals 3 Check bleeder valve metric Remove and replace if damaged CLEANING AND INSPECTION 11WARNING 1WARNING Clean brake system components using denatured alco hol...

Page 100: ...ke pads for damage or excessive wear Replace both pads as a set if the friction material of either pad is worn to 0 04 in 1 0 mm or less ASSEMBLY 1 See Figure 2 39 Install pistons and O rings a Apply a light coat of D O T 4 BRAKE FLUID to seals pistons and caliper piston bores b Install two new seals in outer grooves of each piston bore c Install two new seals in inner grooves of each piston bore ...

Page 101: ...itches may ren der them inoperative 6 See Figure 2 40 Remove both master cylinder cover screws 2 Remove master cylinder cover 1 and gasket 7 With the master cylinder in a level position verify that the brake fluid level is 0 125 in 3 2 mm from molded boss inside reservoir Add D O T 4 BRAKE FLUID if neces sary 11WARNING 1WARNING Verify proper operation of the master cylinder relief port A plugged o...

Page 102: ...draulic brake line and master cylinder bore are com pletely clean 1 See Figure 2 41 Connect brake line to master cylinder using two new banjo washers 2 and banjo bolt 1 metric Loosely install bolt into master cylinder 2 From the master cylinder the brake line runs downward in front of the right handlebar where it turns inboard at the upper triple clamp Loosely install clamp 5 with screw 4 to attac...

Page 103: ...clevis 11 a Spin locknut 10 away from top surface of clevis b Turn rod adjuster 7 to free rod from clevis 11 4 See Figure 2 44 Remove two screws 2 and spacers 3 to detach master cylinder from footrest support 5 See Figure 2 45 Detach remote reservoir DISASSEMBLY NOTE Do not disassemble master cylinder unless problems are experienced Discard all seals during the disassembly proce dure Install a com...

Page 104: ... between master cylinder and footrest sup port Tighten to 4 6 ft lbs 5 8 Nm 11WARNING 1WARNING Use only new black banjo washers See Parts Catalog for Part No with D O T 4 brake fluid Earlier silver banjo washers are not compatible with D O T 4 fluid and will not seal properly over time Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or s...

Page 105: ...GN Apply rear brake pedal to test brake lamp operation Turn ignition key switch to LOCK 11WARNING 1WARNING Always test motorcycle brakes at low speed after servic ing or bleeding system If brakes are not operating prop erly or braking efficiency is poor testing at high speeds could result in death or serious injury Figure 2 45 Remote Reservoir Figure 2 46 Master Cylinder Internals 7703 6506 1 2 3 ...

Page 106: ...caliper from mount 4 See Figure 2 48 Remove clip 1 from rear caliper mount 2 if necessary DISASSEMBLY 1 See Figure 2 47 Remove pin plug and pad hanger 5 metric to free brake pads 2 See Figure 2 48 Remove clip 1 from caliper body 3 See Figure 2 49 Remove piston 3 using BRAKE CALI PER PISTON REMOVER 1 Part No B 42887 with adaptor 2 4 Remove two O rings from groove in caliper bore Discard O rings Fig...

Page 107: ...ll pad hanger pin metric Tighten to 11 15 ft lbs 15 20 Nm b Install pin plug Tighten to 1 5 2 1 ft lbs 2 3 Nm 4 Install a new bleeder valve metric if necessary Tighten to 3 5 ft lbs 4 7 Nm INSTALLATION 1 See Figure 2 48 Install caliper mount clip 1 if removed 2 See Figure 2 47 Install caliper assembly on caliper mount Brake pad surfaces must face rear brake rotor a Apply LOCTITE THREADLOCKER 271 r...

Page 108: ...id Chattering sound when brake is applied Worn pads Replace brake pads Loose mounting bolts Tighten bolts Warped rotor Replace rotor Ineffective brake lever pedal travels to limit Low fluid level Fill master cylinder with approved brake fluid and bleed system Piston cup not functioning Rebuild cylinder Ineffective brake lever pedal travel normal Distorted or glazed rotor Replace rotor Distorted gl...

Page 109: ...ve the bolt 1 and nut 4 from the bottom mount 7 Remove shock absorber assembly INSTALLATION 1 See Figure 2 51 Place new damper bushings 2 into mounting holes of shock absorber if not installed 2 See Figure 2 51 Loosely install bottom bolt and nut 3 Loosely install top bolt and nut NOTE Torque bolts and nuts from the bolt side only 4 Tighten bottom bolt to 35 40 ft lbs 47 54 Nm 5 Tighten top bolt t...

Page 110: ...ted in step 9 2 Connect cables at carburetor 3 Attach throttle cable clamp Use LOCTITE THREAD LOCKER 222 purple on screw 4 Position ferrules on cable wheel 5 Insert idle control into front switch housing 6 Slide switch housing over throttle 7 Insert throttle cable into front switch housing 8 Attach rear switch housing and position housings on right handlebar by engaging locating pin on front housi...

Page 111: ...2 36 2002 Buell P3 Chassis HOME NOTES ...

Page 112: ...l filled damping mechanism controls the telescoping action of each tube slider assembly Figure 2 54 Front Fork Assembly a0073xSx 12 13 14 15 16 17 18 19 11 1 2 3 4 5 6 8 9 20 21 7 22 10 1 Slider Tube Cap 2 Stopper Ring 3 B Spring Seat 4 O ring 5 Spring Collar 6 Lower Spring Seat 7 Spring 8 Damper Assembly 9 Lock Piece 10 Rebound Spring 11 Slide Bushing 12 Dust Seal 13 Retaining Ring 14 Oil Seal Sp...

Page 113: ...fender See 2 23 FENDERS 5 See Figure 2 55 Loosen head lamp bracket screws 6 See Figure 2 56 Loosen the large pinch screws on both the upper and lower triple clamps 7 See Figure 2 57 Remove front fork Repeat procedure for the other front fork Figure 2 55 Headlamp Brackets Figure 2 56 Pinch Screws Figure 2 57 Front Fork Removal a0065aSx Headlamp Bracket Screws 3765 Upper Triple Clamp Lower Triple Cl...

Page 114: ...ork in a vise with front fork holding tool part no B 4177 3 See Figure 2 59 Remove slider tube cap 4 See Figure 2 60 Push down on the B spring seat O ring included and remove the stopper ring and spring seat Figure 2 58 Clamping the Fork Figure 2 59 Slider Tube Cap Figure 2 60 B Spring Seat 3767 3768 3769 ...

Page 115: ...2 Remove the fork oil by pumping the fork leg and rod 8 10 times until the rod moves freely 7 See Figure 2 63 Remove the center bolt metric from the bottom of the fork tube Figure 2 61 Removing Sub Assembly Figure 2 62 Pumping Fork Oil Figure 2 63 Removing Center Bolt 1 Spring Collar 2 Lower Spring Seat 3 Spring a0006xSx 1 2 3 3770 3771 ...

Page 116: ...atched tubes may leak fork oil and then must be replaced 9 See Figure 2 65 Remove the dust seal and the retaining ring from the slider tube 10 See Figure 2 66 Pull the slider tube out of the slider assembly Remove oil seal back up ring and guide bush ing Figure 2 64 Removing Damper Figure 2 65 Removing Dust Seal Figure 2 66 Removing Slider Tube 3772 3775 3773 Oil Seal Backup Ring Guide Bushing ...

Page 117: ...e bushing for excessive wear or scratches Replace if damaged or worn 4 Replace the retaining ring if distorted 5 Measure spring free length Replace springs shorter than service wear limit of 12 8 in 325 mm 6 Measure rebound spring free length Replace springs shorter than service wear limit of 69 in 17 4 mm 7 See Figure 2 69 Measure slide pipe runout Replace pipe if runout exceeds the service wear ...

Page 118: ...ling grease 2 See Figure 2 70 Install slide bushing onto the slide pipe 3 See Figure 2 71 Install damper assembly and rebound spring into slider tube 4 See Figure 2 72 Install lock piece into damper Figure 2 70 Install Slide Bushing Figure 2 71 Damper Assembly Figure 2 72 Lock Piece 3782 3794 3791 ...

Page 119: ...slider tube into slider assembly CAUTION The outer tube can move freely up and down on the slide pipe Always hold both the slide pipe and outer tube to prevent damage to bushings and seals 7 See Figure 2 75 Install spring onto damper assembly Figure 2 73 Clamping the Slider Assembly Figure 2 74 Slider Tube Figure 2 75 Install Rebound Spring 3792 3790 3796 ...

Page 120: ...ing grease 10 See Figure 2 77 Install guide bushing onto the slide pipe 11 See Figure 2 78 Wrap the end of the slide pipe and the slide bushing channel with tape to avoid damaging the oil seal lip when installing Figure 2 76 Install Center Bolt Figure 2 77 Install Guide Bushing Figure 2 78 Slider Tube Protection 3793 3774 3781 ...

Page 121: ...IVER Part No B 43991 drive the guide bushing with the oil seal spacer and oil seal into position in the slider assembly 15 See Figure 2 81 Install retaining ring Verify ring is under groove inside slider assembly 16 See Figure 2 82 Install new dust seal onto slide pipe Figure 2 79 Oil Seal and Backup Ring Figure 2 80 Fork Seal Driver Figure 2 81 Install New Retaining Ring 3785 3787 3786 Retaining ...

Page 122: ... lower spring seat and spring collar 20 Coat a new O ring with fork oil or sealing grease 21 Install new O ring onto spring seat 22 See Figure 2 84 Push down on spring seat past groove to install stopper ring Stopper ring will lock into groove when installed correctly Figure 2 82 Install New Dust Seal Figure 2 83 Remove Slider Tube Protection Figure 2 84 Compressing Spring Seat 3788 3781 3769 ...

Page 123: ...er triple clamps NOTE When installing the front forks use a screwdriver to pry apart the triple clamps 2 See Figure 2 87 Apply LOCTITE ANTI SEIZE to the threads of triple clamp pinch screws 3 See Figure 2 88 Align and secure fork tubes Figure 2 85 Slider Tube Cap Figure 2 86 Installing Fork Tube Figure 2 87 Triple Clamp Pinch Screw 3768 3766 3777 Anti Seize ...

Page 124: ...t lbs 18 22 Nm c Tighten lower triple clamp pinch screws to 22 29 ft lbs 30 39 Nm d See Figure 2 89 Tighten head lamp brackets flush against bottom of top triple clamp 4 Install front fender See 2 23 FENDERS 5 Install front wheel See 2 5 FRONT WHEEL 6 Install front brake caliper See 2 11 FRONT BRAKE CALIPER 7 Align head lamp See 7 17 HEADLAMP Figure 2 88 Pinch Screws Figure 2 89 Tighten Head lamp ...

Page 125: ... HEAD BEARING RACE INSTALLER Part No HD 39302 2 Liberally coat the bearing cones 1 with grease using WHEEL BEARING PACKER TOOL Part No HD 33067 Work the grease into the rollers 3 Install lower bearing a Place lower bearing dust shield 3 over fork stem b Find a section of pipe having an inside diameter slightly larger than the outside diameter of the fork stem c Press bearing 1 with small end up on...

Page 126: ... clutch and throttle cables do not bind when mea suring bearing resistance Lubrication At 10 000 miles 16 100 km and every 10 000 miles 16 100 km thereafter lubricate the steering head bearings with WHEEL BEARING GREASE Part No 99855 89 ADJUSTMENT 1 Detach clutch cable at handlebar 2 Remove seat and fuel tank See 4 2 FUEL TANK COVER FUEL TANK 3 Attach lifting straps to frame backbone behind steeri...

Page 127: ...ngarm bolt 6 and install Torque to 24 26 ft lbs 33 35 Nm 3 Apply LOCTITE 243 BLUE to pinch bolt 1 and install Torque to 17 19 ft lbs 23 26 Nm 4 Install well nuts 5 Install rear shock and fastener Torque to 35 40 ft lbs 47 54 Nm 6 Install rear wheel axle brakes and spacers Torque rear axle nut to 48 52 ft lbs 65 71 Nm 11WARNING 1WARNING After completing repairs or bleeding the system always test mo...

Page 128: ...t System Assembly 1 Gasket Exhaust Port 2 Retaining Ring Exhaust 3 Clamp Exhaust Ring 4 Bolt 5 Screw 6 Screw 7 Washer 6 8 Spacer 9 Spacer Right 10 Spacer Left 11 Spacer 12 Nut 2 13 Nut 2 14 Muffler Complete 15 Muffler Strap Rear 16 Bracket 2 17 Grommet 2 4 12 7 6 12 3 2 14 7 8 15 13 1 17 11 10 16 9 16 7 17 7 5 7 7 a0160x2x ...

Page 129: ... ring may crack if not oriented as stated in step 3 4 Install new exhaust port gasket 1 5 Position muffler on motor Hand tighten nuts 13 6 Slide muffler over bushings on front mount 7 Hand thread bolt washer and nut to front muffler support 8 Install rear muffler strap 15 NOTE A rubber mallet may be used to tap the muffler strap into muf fler notches 9 Install right side muffler spacers 9 brackets...

Page 130: ...ee Figure 2 95 On left side install p clamp with oil tank drain hose and breather hose 4 On right side install rear master cylinder spacers reser voir and brake pedal See 2 13 REAR BRAKE MASTER CYLINDER 5 Install seat See 2 28 SEAT 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation causi...

Page 131: ...TITE THREADLOCKER 243 Blue to threads of three screws 2 Position sprocket cover and install three screws and washers Tighten fasteners to 30 36 in lbs 3 4 Nm 3 Move pedal assembly in position and install pedal bolt Torque pedal bolt to 6 8 ft lbs 8 11 Nm 4 Install master cylinder bolts and spacers See 2 13 REAR BRAKE MASTER CYLINDER Figure 2 96 Master Cylinder Mounting Figure 2 97 Sprocket Cover 7...

Page 132: ...ort See 2 21 FOOT PEGS AND FOOTPEG SUPPORT BRACKETS 3 See Figure 2 100 Remove rear fender mounting screws and washers from rear fender 4 Remove rear fender REAR FENDER INSTALLATION 1 Position rear fender 2 Install rear fender mounting screws washers and well nuts on rear fender 3 Tighten rear fender mounting screws to 30 36 in lbs 3 4 Nm 4 Install right side footrest support bracket See 2 21 FOOTP...

Page 133: ... ers securing lower belt guard to swingarm 2 Remove belt guard INSTALLATION 1 Position belt guard over tabs on swingarm 2 Secure belt guard with two screws and nylon washers 3 Tighten screws to 30 36 in lbs 3 4 Nm Figure 2 101 Lower Belt Guard a0132x2x Lower Belt Guard Nylon Washers 2 Screws 2 30 36 in lbs 3 4 Nm ...

Page 134: ...y negative cable 6 Unplug taillight 7 Cut tie wrap holding taillight and turn signal wires 8 Unplug turn signals 9 Remove nut 8 and washer 7 10 Remove turn signals 6 11 Remove nuts and flat washers from back of taillight 12 Remove taillight 13 Remove bolts 4 and nuts 9 14 Remove license plate bracket 5 Figure 2 102 Tail Section 1 Tail Section Fairing 2 Tree Fastener 3 Bolt 4 Bolt 5 License Plate B...

Page 135: ...nnect rear wire harness and mount on T stud INSTALLATION TAIL SECTION 1 Install license plate bracket 5 using fasteners 4 and nuts 9 in rear holes 2 Install taillight using flat washers and nuts 3 Install turn signals 6 using lock washers 7 and nuts 8 4 Connect turn signal wires and taillight wires Cable tie together 5 Install tail section 1 using fasteners 3 19 20 6 Connect battery negative cable...

Page 136: ...See Figure 2 104 Remove windscreen trim 4 Remove windscreen mounting brackets INSTALLATION 1 If removed install both windscreen brackets See 7 17 HEADLAMP 2 Verify trim is installed on windscreen 3 Install two screws and nylon washers on each side Tighten screws to 9 11 in lbs 1 Nm Figure 2 103 Remove Screws Figure 2 104 Windscreen Trim 3779 3797 ...

Page 137: ... NOTE To remove speedometer see 7 25 ELECTRONIC SPEED OMETER INSTALLATION 1 Install odometer reset switch to instrument panel and install rubber boot 2 Install connector 39 on back of speedometer 3 Apply LOCTITE THREADLOCKER 243 Blue to threads of mounting screws Install dash with two mounting screws Tighten screws to 30 36 in lbs 3 4 Nm Figure 2 105 Instrument Panel a0154x2x Screws 2 Odometer Res...

Page 138: ...he seat with one hand and grasp the front section of the seat with the other hand 3 See Figure 2 109 Push seat forward while flexing the rear section of the seat upward until the tongue locks into the bracket located on the frame 4 Push down firmly on the seat NOTE You will hear a click when the locating tab and seat latch lock together correctly 5 Ensure seat is locked in position 11WARNING 1WARN...

Page 139: ...r interlock system INSPECTION 1 Test the side stand with the vehicle upright and level The side stand should move freely into extended down and up position 2 Check side stand switch operation after first 1000 miles and every 2500 miles DISASSEMBLY REMOVAL 1 Raise rear wheel off floor using REAR WHEEL SUP PORT STAND Part No B 41174 2 Disconnect electrical connection a Press Tab indent b Pull connec...

Page 140: ... 14 16 Nm 4 Install master cylinder Tighten master cylinder clamp bolts to 80 120 in lbs 9 14 Nm 5 Install throttle grip 6 Hook ferrels to cable wheel Position cables in notches of switch housing 14 7 Position housings on right handlebar Front housing has locating pin that must align with hole in handlebar Install fasteners longer screw on bottom Tighten fasteners to 25 33 in lbs 3 4 Nm 8 Plug in ...

Page 141: ... See Figure 2 113 Position new isolator in frame 2 Install two outboard isolator bolts 1 Torque 30 33 ft lbs 41 45 Nm 3 Install main isolator bolt and new nut 2 Tighten main isolator bolt to 63 70 ft lbs 85 95 Nm 4 Tighten front ground strap bolt to 30 33 ft lbs 41 45 Nm 5 Install clutch cable to clip 6 Install horn tie wrap 7 Install fuel tank See 4 2 FUEL TANK COVER FUEL TANK 11WARNING 1WARNING ...

Page 142: ...r Installation 1 Clean engine bolt holes and bolts Do not re tap holes 2 Apply LOCTITE 243 BLUE to bolts and install four isola tor to engine bolts Torque bolts to 32 34 ft lbs 46 50 Nm 3 Apply LOCTITE 272 RED to the two frame to isolator bolts Torque bolts to 30 33 ft lbs 41 45 Nm 4 Install rear shock absorber See 2 15 REAR SHOCK ABSORBER 11WARNING 1WARNING Always connect positive battery cable f...

Page 143: ...2 68 2002 Buell P3 Chassis HOME NOTES ...

Page 144: ...2002 Buell P3 Chassis 2 69 HOME ...

Page 145: ...6 Cylinder And Piston 3 35 3 7 Lubrication System 3 43 3 8 Oil Hose Routing 3 44 3 9 Oil Reservoir 3 45 3 10 Oil Pressure Indicator Switch 3 46 3 11 Crankcase Breathing System 3 47 3 12 Oiling System 3 48 3 13 Oil Pump 3 49 3 14 Oil Filter Mount 3 52 3 15 Hydraulic Lifters 3 53 3 16 Gearcase Cover And Cam Gears 3 55 3 17 Crankcase 3 64 ENGINE 3 Table Of Contents ...

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Page 147: ......

Page 148: ... in guide Exhaust 0 0015 0 0033 in 0 0381 0 0838 mm 0 0040 in 0 1016 mm Intake 0 0008 0 0026 in 0 0200 0 0700 mm 0 0035 in 0 0889 mm Seat width 0 040 0 062 in 1 016 1 575 mm 0 090 in 2 286 mm Stem protrusion from cylinder valve pocket 1 975 2 011 in 50 165 51 079 mm 2 031 in 51 587 mm OUTER VALVE SPRING NEW COMPONENTS SERVICE WEAR LIMITS Free length 2 105 2 177 in 53 467 55 296 mm 2 105 in min 53 ...

Page 149: ...0 in 0 02540 mm CYLINDER HEAD NEW COMPONENTS SERVICE WEAR LIMITS Valve guide in head tight 0 0033 0 0020 in 0 0838 0 0508 mm Valve seat in head tight 0 0035 0 0010 in 0 0889 0 0254 mm Head gasket surface flatness 0 006 in total 0 152 mm total 0 006 in total 0 152 mm total CYLINDER NEW COMPONENTS SERVICE WEAR LIMITS Taper 0 002 in 0 051 mm Out of round 0 003 in 0 076 mm Warpage gasket surfaces Top ...

Page 150: ...m Intake cam gear shaft end play min 0 006 0 024 in 0 152 0 610 mm 0 040 in 1 016 mm FLYWHEEL NEW COMPONENTS SERVICE WEAR LIMITS Runout Flywheels at rim 0 000 0 010 in 0 000 0 254 mm 0 010 in 0 254 mm Shaft at flywheel end 0 000 0 002 in 0 000 0 051 mm 0 002 in 0 051 mm End play 0 001 0 005 in 0 025 0 127 mm 0 005 in 0 127 mm SPROCKET SHAFT BEARING NEW COMPONENTS SERVICE WEAR LIMITS Outer race fit...

Page 151: ...ter adapter 8 12 ft lbs 11 16 Nm LOCTITE thread locker 243 blue Page 3 52 Oil pressure signal light switch 50 70 in lbs 6 8 Nm Page 3 52 Oil pump cover screws 70 80 in lbs 8 9 Nm TORX page 3 51 Oil pump mounting screws 125 150 in lbs 14 17 Nm Page 3 51 Pinion shaft nut 19 21 ft lbs 26 29 Nm Page 3 62 Pushrod cover screw 30 40 in lbs 3 5 Nm Page 3 54 Rear engine isolator engine to crankcase 23 27 f...

Page 152: ...uide Oil is transferred to the teeth of all the cam gears by way of the gear meshing action The oil scavenging section of the pump returns oil to the tank from the engine See 3 7 LUBRICATION SYSTEM for more information ADJUSTMENT TESTING General When an engine needs repair it is not always possible to determine definitely beforehand whether repair is possible with only cylinder head cylinder and p...

Page 153: ...ylinder being tested must be at top dead center of compression stroke during test 6 To keep engine from turning over when air pressure is applied to cylinder engage transmission in fifth gear and lock the rear brake 7 Following the manufacturer s instructions perform a cyl inder leakage test on the front cylinder Make a note of the percent leakdown Any cylinder with 12 leakdown or more requires fu...

Page 154: ...ck under the motor Use jack to lower motor 7 Remove Horn See 7 22 HORN 8 See Figure 3 1 Remove crankcase breather hose and crankcase breather from rocker box grommet CAUTION See Figure 3 2 Do not attempt to remove isolator mount from cylinder head Isolator mount is an integral compo nent and is not meant to be removed unless absolutely necessary Repeated removals and installations will damage cyli...

Page 155: ...ut do not remove lower front tie bar bolts at engine and frame 12 For engine removal loosen and remove lower front tie bar from engine 13 See Figure 3 4 Remove top rear tie bar at frame Figure 3 3 Front Isolator Mount Figure 3 4 Remove Top Rear Tie Bar 1 Frame 2 Locknut 3 Snubber 4 Bolt 5 Spacer 6 Front Isolator 7 Standoff 1 a0162x6x 2 3 4 5 6 7 7627 ...

Page 156: ...3 AIR CLEANER for more details about the air cleaner See 3 5 CYLINDER HEAD The steps mentioned previously complete disassembly preparation for top end servicing You may now proceed with TOP END DISASSEMLY PROCEDURES If continuing engine removal proceed to step 16 Figure 3 5 Air Cleaner Assembly 1 2 a0074x3x 1 Air cleaner bracket left front 2 Air cleaner bracket right rear 3 Air cleaner screw 3 Fig...

Page 157: ...n rear sprocket off pulley toward inside of motorcycle 21 See Figure 3 10 Remove right side rider footpeg bracket assembly See 2 21 FOOTPEGS AND FOOTPEG SUP PORT BRACKETS 22 Introduce freeplay and remove clutch cable at hand lever location See 6 4 CLUTCH 23 See Table 3 3 Disconnect the following electrical items Figure 3 9 Brake Line Assembly 1 Screw 2 Brake fluid reservoir 3 Screw 4 Brake line br...

Page 158: ...rame backbone 2 Speedo sensor 65 Located under seat right side tucked in under cavity 3 Side stand switch 60 Tie wrapped to rear brake line 4 Neutral switch 131 Disconnect at neutral switch 5 Oil pressure switch 120 Disconnect at oil pressure switch 6 Alternator stator 46 Located under seat left side 7 Starter solenoid wire 128 Disconnect at starter 8 Spark plug wire Located on spark plug 9 Batter...

Page 159: ...move chassis from engine by performing the steps below a Lower chassis b Disconnect hoist from chassis c Lower lift d See Figure 3 15 Lift chassis and roll away from engine Figure 3 13 Disconnect Lines Figure 3 14 Removing Rear Motor Mount Bolts Figure 3 15 Move Chassis From Engine 7634 1 Oil Return 2 Transmission Vent 3 Crankcase Vent 4 Oil Feed 4 2 1 3 7623 7651 ...

Page 160: ...ME 30 See Figure 3 16 Remove air cleaner box bracket 31 See Figure 3 17 Remove rear engine mount 32 See Figure 3 18 Loosen swingarm pinch bolt Figure 3 16 Bracket Figure 3 17 Rear Engine Mount Figure 3 18 Pinch Bolt 7652 7653 7654 ...

Page 161: ...Figure 3 19 Remove swingarm pivot shaft and rear wheel as an assembly See 2 19 SWINGARM 34 See Figure 3 20 Remove side stand and bracket assembly See 2 29 SIDE STAND Figure 3 19 Swingarm Pivot Shaft Figure 3 20 Side Stand Bracket 7655 7656 ...

Page 162: ...ads b Tighten to 38 41 ft lbs 51 55 Nm 3 Install rear wheel See 2 6 REAR WHEEL See Figure 3 22 Install swingarm pivot shaft and rear wheel as an assembly See 2 19 SWINGARM a Tighten to 24 26 ft lbs 32 35 Nm 4 See Figure 3 23 Install swingarm pinch bolt a Apply several drops of LOCTITE THREAD LOCKER 243 blue to last few threads b Tighten to17 19 ft lbs 23 26 Nm Figure 3 21 Side Stand Bracket Figure...

Page 163: ...ll chassis onto engine by performing the steps below a See Figure 3 26 Roll chassis toward engine b Lift chassis onto engine c Raise lift d See Figure 3 27 Attach hoist to frame Place a floor hoist behind the lift Attach straps to frame and hoist Raise hoist until straps tighten 8 Place jack under the motor Use jack to raise motor 9 Move jack backward Figure 3 24 Rear Engine Mount Figure 3 25 Brac...

Page 164: ...OCKER 262 red to last few threads b Tighten to 30 33 ft lbs 41 45 Nm 11 See Figure 3 29 Connect feed return transmission and crankcase vent lines Figure 3 27 Hoisting Bike Figure 3 28 Installing Rear Motor Mount Bolts Figure 3 29 Connect Lines 7650 7623 7634 1 Oil return 2 Transmission vent 3 Crankcase vent 4 Feed 4 2 1 3 ...

Page 165: ...s for Engine Assembly Item no Description Location 1 Ignition module 10 Located on frame backbone 2 Speedo sensor 65 Located under seat right side tucked in under cavity 3 Side stand switch 60 Tie wrapped to rear brake line 4 Neutral switch 131 Disconnect at neutral switch 5 Oil pressure switch 120 Disconnect at oil pressure switch 6 Alternator stator 46 Located under seat left side 7 Starter sole...

Page 166: ...b Tighten to 4 6 ft lbs 5 8 Nm NOTE SEE TOP END ASSEMBLY SECTION The steps mentioned previously complete Assembly preparation for top end servic ing You may now proceed with TOP END ASSEMBLY PRO CEDURES Then proceed to step 22 Figure 3 32 Brake Line Assembly Figure 3 33 Footpeg Bracket Assembly 1 Screw 2 Brake Fluid Reservoir 3 Screw 4 Brake Line Bracket 5 Screw 6 Brake Line 7 Master Cylinder 8 Sp...

Page 167: ... 3 36 Install and tighten screws on both air cleaner brackets f Install screw on air cleaner cover NOTE See 4 3 AIR CLEANER for more details on the air cleaner Figure 3 34 Auto Enrichener Plug Figure 3 35 Crankcase Breather Hose 1 Auto Enrichener Plug 2 Frame 2 1 7631 7649 1 Breather Hose 2 Three way Connector 1 2 Figure 3 36 Air Cleaner Assembly Figure 3 37 Hose Clamp 1 Air Cleaner Bracket left f...

Page 168: ...all the two mounted cylinder head bolts from the front isolator engine bracket marked DO NOT REMOVE a Apply several drops of LOCTITE THREAD LOCKER 262 red to last few threads of new bolts b Apply a thin film of clean HD 20W50 engine oil to both sides of new thick washers and to bottom of bolt heads Exercise caution to avoid mixing oil on washers with LOCTITE on bolts c Tighten bolts to 60 ft lbs 2...

Page 169: ...oil and primary chaincase fluid as necessary 35 See Figure 3 33 Install right side rider footpeg bracket assembly See 2 21 FOOTPEGS AND FOOTPEG SUP PORT BRACKETS 11WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury...

Page 170: ... be closed when viewed through the spark plug hole 6 Remove the two rocker arm retaining bolts near the push rods 7 Remove remaining hardware holding lower rocker cover to cylinder head in the following order a Remove two screws and washers b Remove three bolts and washers c Remove the remaining two rocker arm retaining bolts Figure 3 43 Rocker Arm Cover 1 Crankcase Breather 2 Grommet 3 Screw 4 4 ...

Page 171: ...own 13 Support motorcycle under crankcase Do not allow engine to drop when performing the next Step 14 Continue loosening in 1 8 turn increments until screws are loose Remove head screws 15 Remove cylinder head head gasket and O rings 16 Discard head gasket 17 See Figure 3 43 Remove push rod cover gasket and valve tappets DISASSEMBLY 1 See Figure 3 46 Compress valve springs with VALVE SPRING COMPR...

Page 172: ...ring 6 Outer valve spring 7 Valve seal 8 Lower valve spring collar 9 Valve guide intake exhaust 2 10 Cylinder head 11 Exhaust port stud 12 Cylinder head gasket 13 Cylinder O ring 4 14 Cylinder insert 15 Cylinder w piston rings 16 Cylinder base gasket 17 Cylinder base stud 18 Exhaust valve 19 Exhaust valve seat 1 2 a0021x3x 3 4 5 6 7 8 9 15 10 11 12 13 14 16 17 15 18 19 ...

Page 173: ...r other hardened tool which could scratch or nick valve Polish valve stem with very fine emery cloth or steel wool 4 Check each rocker arm at pad end and push rod end for uneven wear or pitting Replace rocker arm if either condition exists 5 Measure and record rocker arm shaft diameter a See Figure 3 48 Measure where shaft fits in lower rocker arm cover b See Figure 3 49 Measure where rocker arm b...

Page 174: ...b guides with VALVE GUIDE BRUSH Part No HD 34751 and hot soapy water Measure valve stem outer diameter and valve guide inner diameter Check mea surements against SERVICE WEAR LIMITS 15 Inspect spark plug threads for damage If threads in head are damaged a special plug type insert can be installed using a 12 mm spark plug repair kit 16 Inspect valve springs for broken or discolored coils 17 See Fig...

Page 175: ...into bushing From opposite side of rocker arm press out bushing and tap 2 Press replacement bushing into rocker arm flush with arm end and split portion of bushing towards top of arm 3 Using remaining old bushing as a pilot line ream new bushing with ROCKER ARM BUSHING REAMER Part No HD 94804 57 4 Repeat for other end of rocker arm Figure 3 54 Removing Rocker Arm Bushing 9 16 in 18 tap 2411a ...

Page 176: ... the correct guide height has been reached 5 Ream guides to final size or within 0 0010 in 0 0254 mm of final size using VALVE GUIDE REAMER Steel Part No HD 39932 or Carbide Part No HD 39932 CAR Use REAMER LUBRICANT Part No HD 39964 or liberal amounts of suitable cutting oil to pre vent reamer chatter NOTE The hone is not intended to remove material 6 Apply the proper surface finish to the valve g...

Page 177: ...marks Cut or grind only enough to clean up the seat 2 Apply a small amount of lapping compound to the valve face Rotate valve against seat using VALVE LAPPING TOOL Part No HD 96550 36A 3 See Figure 3 57 Check the contact pattern on valve face It should be 0 040 0 062 in 1 016 1 575 mm wide and its center should be positioned 2 3 of the way toward the outside edge of face 4 If valve seat pattern is...

Page 178: ...R HEAD HOLDING FIX TURE Part No HD 39786 to secure cylinder head a Apply a light coat of fine lapping compound to valve face Insert valve in guide b Place one rubber cup end of VALVE LAPPING TOOL Part No HD 96550 36A onto head of valve c Holding lapping tool as shown apply only very light pressure against valve head d Rotate lapping tool and valve alternately clockwise and counterclockwise a few t...

Page 179: ...m keeper groove when installing valve stem seal If the seal is installed without using the protective sleeve the seal will be damaged Do not remove valve after seal is installed Other wise sharp edges on keeper groove will damage seal 7 See Figure 3 61 Tap the valve stem seal onto the valve guide using the VALVE SEAL INSTALLATION TOOL Part No HD 34643A and DRIVER HANDLE Part No HD 34740 The seal i...

Page 180: ...the head screws is critical to proper distribution of pressure over gasket area It prevents gasket leaks stud failure and head and cylin der distortion 10 See Figure 3 45 For each cylinder head start with screw numbered one as shown In increasing numerical sequence i e 1 2 3 and 4 a Tighten bolts to 8 10 ft lbs 11 14 Nm b Tighten bolts to 13 15 ft lbs 18 20 Nm c Loosen all screws 11 After screws a...

Page 181: ...18 Nm 16 See Figure 3 65 Install upper rocker covers a Place a new inner gasket on lower rocker box assembly b Place a new lower gasket on lower rocker cover c Install upper rocker cover using screws with wash ers and new fiber seals Tighten screws to 10 14 ft lbs 13 6 9 Nm Table 3 8 Lower Rocker Box Hardware ITEM SIZE TORQUE Bolt with washer 12 5 16 18 X 2 3 4 18 22 ft lbs 24 30 Nm Bolt with wash...

Page 182: ... to bend the cylin der studs The slightest bend could cause a stress riser and lead to stud failure 7 Install a 6 0 in 152 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the piston 11WARNING 1WARNING Retaining rings are highly compressed in the ring groove and may fly out with considerable force when pried out Always wear safety glasse...

Page 183: ...hing has a 0 00125 to 0 00175 in 0 03175 0 04445 mm clearance in bushing b See Connecting Rod Bushing section If piston pin to bushing clearance exceeds 0 00200 in 0 05080 mm replace worn parts 6 Clean piston pin retaining ring grooves 7 Examine piston and cylinder for cracks burnt spots grooves and gouges 8 Check connecting rod for up and down play in lower bearings When up and down play is detec...

Page 184: ...cylinder taper or bulge 5 See Table 3 9 If cylinder is not scuffed or scored and is within service limit see FITTING CYLINDER TO PIS TON section NOTE See 3 1 SPECIFICATIONS If piston clearance exceeds ser vice wear limit cylinders should be re bored and or honed to next standard oversize and refitted with the corresponding piston and rings Do not fit piston tighter than 0 0007 in 0 0178 mm Measuri...

Page 185: ...e Figure 3 71 Piston rings are of two types compression and oil control The two compression rings are positioned in the two upper piston ring grooves The dot on the second compression ring must face upward Ring sets are available to fit standard and oversize pistons Piston ring sets must be properly fitted to piston and cylinder 1 See 3 1 SPECIFICATIONS See Figure 3 72 Place pis ton in cylinder ab...

Page 186: ...e when installing rings NOTE Install second compression ring with dot towards top 3 See Figure 3 74 Install rings so end gaps of adjacent rings are a minimum of 90 apart Ring gaps are not to be within 10 of the thrust face centerline 4 See 3 1 SPECIFICATIONS See Figure 3 75 Check for proper side clearance with thickness gauge as shown NOTE If the ring grooves are clean and the side play is still n...

Page 187: ...lean up and size bushing to 0 0010 0 0005 in 0 0254 0 0127 mm undersize using REAMER Part No HD 94800 26A Sizing bushing with less than 0 00125 in 0 03175 mm clearance can result in a bushing loosening and or seized pin in rod 8 Hone bushing to final size using WRIST PIN BUSHING HONE Part No HD 35102 Use a liberal amount of honing oil to prevent damage to hone or bushing Use care to prevent foreig...

Page 188: ...on groove and damage cylinder and piston beyond repair 4 See Figure 3 79 Install new piston pin retaining rings 1 using PISTON PIN RETAINING RING INSTALLER 2 Part No HD 34623B Place new retaining ring on tool with gap pointing up See Figure 3 80 NOTE Make sure the ring groove is clean Ring must be fully seated in the groove with the gap away from the slot at the bottom 5 See Figure 3 74 Make sure ...

Page 189: ...inder base gasket Make sure the piston does not bump the studs or crankcase 10 Install cylinder over piston 11 Remove PISTON RING COMPRESSOR 12 Assemble cylinder head See 3 5 CYLINDER HEAD 13 Install cylinder head See 3 5 CYLINDER HEAD 14 Install assembled engine See 3 4 ENGINE INSTALLA TION Figure 3 81 Piston Support Plate Figure 3 82 Compressing Piston Rings 7658 1 1 Piston Support Plate Part No...

Page 190: ... combustion in a gasoline engine produces water vapor and carbon dioxide along with other gases and particu lates When first starting and warming an engine some of the water vapor that gets into the engine crankcase condenses to form liquid water If the engine is driven long enough to thor oughly warm the crankcase most of this liquid water is again vaporized and exhausted through the crankcase br...

Page 191: ...n hoses run together alongside the engine and forward to the oil pump The feed hose attaches to the rear most oil pump fitting the return hose connects forward and above See Figure 3 86 After diverging from the feed and return hoses the vent hose continues on to the right side of the motorcycle Here the vent hose connects to an elbow fitting on the gearcase cover Figure 3 83 Oil Reservoir Hose Ass...

Page 192: ...servoir From the bottom of the reser voir the vent hose and the return hose run downward below the battery tray A rubberized clamp secure the hoses in place Figure 3 87 Oil Reservoir Frame Backbone a0027a3x 1 3 8 inch Clamp 2 Feed Hose 3 Drain Hose 4 1 4 inch Clamp 5 Vent Hose 6 Return Hose 7 T fitting 8 Dipstick 3 2 6 5 7 1 4 1 1 1 4 1 8 ...

Page 193: ... e thicker When an engine is operated at high speeds the volume of oil circulated through the oiling system increases resulting in higher oil pressure As engine speed is reduced the volume of oil pumped is also reduced resulting in lower oil pressure To check oil pressure use OIL PRESSURE GAUGE Part No HD 96921 52B and OIL PRESSURE GAUGE ADAPTER Part No HD 96940 58 Remove oil pressure indicator sw...

Page 194: ...PCV located on top of the rocker box cover From the PCV the air enters the crankcase breather hose The crankcase breather hose splits with one hose crankcase breather hose going to the air cleaner and the other hose crankcase breather drain hose going to the footrest support bracket Crankcase air is routed to the air cleaner box where it is directed into the carburetor s venturi Any residual oil d...

Page 195: ... intersecting passage in the gearcase cover Oil flow is then routed to the crankshaft area 10 Oil enters a hole in the end of the pinion gear shaft and travels to the right flywheel where it is routed through the flywheel to the crankpin Oil is forced through the crank pin to properly lubricate the rod bearing assembly 11 Oil flows up passages in the push rods to the rocker arm shafts and bushings...

Page 196: ...ck into the pump and is forced by the gerotor scavenge set back to the oil reservoir The oil pump seldom needs servicing Before you disassem ble an oil pump suspected of not producing adequate oil pressure be sure that all possible related malfunctions have been eliminated 1 Make sure all oil hose clamps are tight and that hoses are not pinched or damaged 2 Check level and condition of oil in tank...

Page 197: ...pieces of gerotor scavenge set off gear shaft 9 Remove and discard retaining ring Remove thrust washer and gear shaft CLEANING AND INSPECTION 1 Clean all parts in cleaning solvent Blow out holes and oil passages with compressed air 2 See Figure 3 92 Inspect both gerotor sets for wear a Mesh pieces of each set together as shown b Use a feeler gauge to determine clearance c The SERVICE WEAR LIMIT be...

Page 198: ...otor feed set over gear shaft 7 Place cover onto pump body Install cover TORX screws Tighten to 70 80 in lbs 8 9 Nm 8 Place new mounting gasket in position NOTE Use new hose clamps If fittings were removed use TEFLON PIPE SEALANT or HYLOMAR on fitting threads 9 See Figure 3 91 Attach return hose connection 10 Secure pump to crankcase with mounting screws Tighten to 125 150 in lbs 14 17 Nm 11 Attac...

Page 199: ...NOTE Use TEFLON PIPE SEALANT or HYLOMAR on all fittings installed to oil filter mount 1 See Figure 3 94 Install oil pressure indicator switch using OIL PRESSURE SENDING UNIT WRENCH Part No HD 41675 Tighten to 50 70 in lbs 6 8 Nm 2 Attach indicator lamp wire NOTE The filter adapter has identical ends either end may be installed into the filter mount 3 Apply several drops of LOCTITE thread locker 24...

Page 200: ...ough top of cylinder head See 3 5 CYLIN DER HEAD 3 Remove cylinder head assembly See 3 5 CYLINDER HEAD 4 See Figure 3 96 Remove push rod cover a Remove screws b Remove push rod cover c Remove gasket and o rings Discard parts 5 Remove both valve hydraulic lifters a Remove anti rotation screws b Remove lifters from crankcase bore using a thin bladed screwdriver Mark the location and orienta tion fro...

Page 201: ...ith washers in the holes in lifter block b Tighten anti rotation screws to 55 65 in lbs 6 7 Nm 5 Install push rod cover a Slide new gasket cover over bottom of push rod cover b Position push rod cover onto crankcase c Install screws through holes in push rod cover into tapped holes in crankcase Tighten screws evenly to 30 40 in lbs 3 5 Nm d Place new o rings on top of push rod cover 6 Install push...

Page 202: ...portant to know and understand all inspection procedures and how components interact Figure 3 98 Gearcase Cover Cam Assembly a0030x3x 1 Crankcase Half 2 Dowel Pin 3 Inner Camshaft Gear Bushing 4 W Cam Gear Set 5 Oil Pump Drive Gear 6 W Cam Pinion and Drive Gear Set 7 Nut 8 Gear Shaft Pinion Bushing 9 Cam Gear Shaft Outer Bushing 10 Key 11 Camshaft Cover Gasket 12 Gear Cover 13 Seal 14 Sems Screw 1...

Page 203: ...ake 1W Exhaust See Figure 3 100 Measure the gear diameter with a micrometer over 0 108 in 2 743 mm diameter gauge pins on opposite sides of the gear The pins are of the proper size to fit between the contacting surfaces of the gear teeth Gear diameter should be measured in at least two places 90 apart Use GAUGE PIN SET Part No HD 38361 when measuring pinion and cam gear sizes Cam gears are individ...

Page 204: ...Gear 4 Color Code 1 2 3 4 7687 Table 3 12 Cam and Pinion Gear Color Code and Diameter GEAR NO POSITION 2 INBOARD 2 OUTBOARD 1 3 COLOR CODE 1 paint dot Intake Intake Exhaust Pinion RED 1 9025 1 9029 48 323 48 333 1 9025 1 9029 48 323 48 333 WHITE 1 9020 1 9024 48 310 48 321 1 9020 1 9024 48 310 48 321 GREEN 1 9015 1 9019 48 298 48 308 1 9015 1 9019 48 298 48 308 ...

Page 205: ...its crankcase bore so that bushing shoulder contacts crank case boss 3 See Bushing Reaming After you install a new bushing in right crankcase half ream the bushing to correct size CAM GEAR BUSHINGS EXCEPT INTAKE BUSHING IN GEARCASE COVER 1 See Figure 3 104 Using an arbor press install each bushing in its gearcase cover bore so that bushing shoul der contacts cover boss Position each bushing so the...

Page 206: ...ble rotation within the cover bore by installation of a dowel pin See Figure 3 106 Drill a No 31 hole 0 281 in 7 137 mm deep at top side of boss side toward top of gearcase cover centering the drill bit on the cover bore circle hole is drilled half in bushing OD and half in cover bore ID 3 Drive a new dowel pin no more than 0 20 in 5 08 mm below the bushing face Carefully peen edges of hole to loc...

Page 207: ... Inspect bushings for proper cam gear shaft fit Repeat line reaming operation if necessary Safety glasses or goggles must be worn while removing metal chips shavings Failure to wear safety glasses or goggles could result in death or serious injury 5 Thoroughly clean gearcase cover removing all metal chips shavings Blow out all oil passages using com pressed air INTAKE CAM GEAR BUSHING IN GEARCASE ...

Page 208: ...reamer one com plete clockwise turn to size the bushing Continue turning reamer clockwise while extracting reamer from bushing 4 See Figure 3 109 Separate gearcase cover from right crankcase half Inspect bushing for proper pinion shaft fit Repeat line reaming operation if necessary Safety glasses or goggles must be worn while removing metal chips shavings Failure to wear safety glasses or goggles ...

Page 209: ...ITE thread locker 262 red to last few threads of nut d Install nut to pinion shaft Tighten nut to 19 21 ft lbs 26 29 Nm plus an additional 15 to 17 rotation 3 See Figure 3 101 Liberally apply engine oil to bushings shafts and gears Install all cam gears into bushings of right crankcase half properly aligning timing marks of cam gears and pinion gear NOTE Because of the larger diameter additional g...

Page 210: ... using a flat blade screwdriver c Measure gap between bushing in crankcase half and cam gear shaft thrust face shoulder using a feeler gauge This is cam gear end play d Compare cam gear end play measurements with the SERVICE WEAR LIMITS Make repairs as required if end play does not meet specifications 7 See 3 15 HYDRAULIC LIFTERS Install hydraulic lifters and push rods 8 Install cam position senso...

Page 211: ...ith indicator stem on end of gearshaft 4 To obtain an accurate flywheel end play reading preload sprocket shaft bearings Create a suitable tool by weld ing two handles to an old engine sprocket nut Install the nut and sprocket Tighten to 190 210 ft lbs 258 285 Nm 5 Check flywheel end play a Rotate and push on sprocket shaft while reading dial indicator b Then rotate and pull on sprocket shaft whil...

Page 212: ...RTER Remove starter motor 7 See Figure 3 115 Remove screws and rear engine mount bolts securing crankcase halves together 8 Tap crankcase with plastic mallet to loosen and separate the halves The next step requires using a press Wear eye protec tion and make certain set up is stable The pressure Figure 3 115 Crankcase Hardware 1 Crankcase Set 2 Bottom Case T40 TORX Bolt 5 16 18 X 3 1 2 in long 5 3...

Page 213: ...necessary to remove either the pin ion shaft bearing or sprocket shaft bearing proceed as fol lows 10 Gearshaft bearing will remain on flywheel pinion shaft Remove retaining ring and bearing may be slipped off pinion shaft 11 See Figure 3 118 Place flywheel assembly in FLY WHEEL SUPPORT FIXTURE Part No HD 44385 Pull sprocket shaft bearing with SPROCKET SHAFT INNER Figure 3 116 Pressing Flywheel fr...

Page 214: ... is based on the largest measured outside diameter OD of the inner race and the smallest measured inside diame ter ID of the outer race crankcase bushing A running clearance of 0 0002 0 0008 in 0 0051 0 0203 mm is established during crankcase set or flywheel assembly replacement and engine rebuild Figure 3 118 Removing Sprocket Shaft Roller Bearing 7671 Bearing Race Remover Installer HD 34902B Bea...

Page 215: ...either inner or outer race show wear measure both races to confirm correct bearing fit Figure 3 121 Factory Inner Race Sizes Paint dot on end of spline SERVICE WEAR LIMIT 1 2492 in 31 7297 mm RACE OD CLASS IDENTIFICATION 1 2498 1 2500 in 31 7449 31 7500 mm A White 1 2496 1 2498 in 31 7398 31 7449 mm B Green a0131x3x Inner Race Paint Dot Figure 3 122 Factory Outer Race Sizes Figure 3 123 Bearing Id...

Page 216: ... the following specifi cations ID 1 5646 1 5652 in 39 7408 39 7561 mm Roundness within 0 0002 in 0 0051 mm Taper within 0 0002 in 0 0051 mm Surface finish 16 RMS 7 See Figure 3 125 Pull inner race from pinion shaft using WEDGE ATTACHMENT for CLAW PULLER Part No HD 95637 46A with BEARING RACE REMOVER INSTALLER Part No HD 34902B and END CAP Part No HD 34902 7 Apply heat to race to aid removal 8 See ...

Page 217: ... mm Red Blue White Gray 1 5664 1 5666 in 39 787 39 792 mm Red Blue White Gray Green 1 5662 1 5664 in 39 781 39 787 mm Red Blue White Gray Green 1 5660 1 5662 in 39 776 39 781 mm Red Blue White Gray Green 1 5658 1 5660 in 39 771 39 776 mm Red Blue White Gray Green 1 5656 1 5658 in 39 766 39 771 mm Red Blue White Gray Green 1 5654 1 5656 in 39 761 39 766 mm Red Blue White Gray Green 1 5652 1 5654 in...

Page 218: ...ing or bushing will bell a condition where hole is larger at ends than it is in the center 4 Withdraw arbor far enough to coat lightly with 220 grit lapping compound Do not apply a heavy coat Reposi tion lap in bushing and turn handle at moderate hand speed Work lap back and forth in bushing as it is revolved to avoid grooving and tapering At frequent intervals remove lap from crankcase wash and i...

Page 219: ...e edge of the snap ring at the 10 and 2 o clock positions d Using a 9 64 inch allen head bit tighten the screws to fix the position of the claws on the snap ring e Inserting the tips of a large retaining ring pliers Snap On PR 56A into one hole in each claw com press the snap ring and install in groove of crank case bore f Verify that the gap in the snap ring is centered below the oil hole at the ...

Page 220: ...ase con tacts outboard surface of installed left outer race 6 Position right outer race over bearing bore on inboard side of left crankcase half 7 See Figure 3 129 Insert shaft of installer plug through right outer race and into installer base Press race into bore until firmly seated against retaining ring NOTE See Figure 3 129 Use SPROCKET SHAFT BEARING SEAL INSTALLATION TOOL Part No HD 42579 to ...

Page 221: ...is free 10 See Figure 3 133 Install new spacer in seal ID With the open lipped side facing outward center seal spacer assembly over bearing bore Do not remove the spacer after installation or the new seal will have to be discarded and the procedure repeated 11 See Figure 3 133 Install bearing seal and spacer a Center seal spacer driver over seal so that the sleeve smaller OD seats between seal wal...

Page 222: ...the crankcase with the shoulder end down Use an air gun to drive the stud until the shoulder reaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 16 Install piston and cylinder See 3 6 CYLINDER AND PIS TON 17 Install oil pump See 3 13 OIL PUMP 18 See 3 16 GEARCASE COVER AND CAM GEARS Install cam gears gearcase cover lifter guides and lift ers 19 Insta...

Page 223: ...3 76 2002 Buell P3 Engine HOME NOTES ...

Page 224: ...ecifications 4 1 4 2 Tank Cover Fuel Tank 4 5 4 3 Air Cleaner 4 12 4 4 Carburetor 4 15 4 5 Auto Enrichener 4 22 4 6 Throttle Position Sensor 4 25 4 7 Evaporative Emissions Control System 4 27 FUEL SYSTEM 4 Table Of Contents ...

Page 225: ......

Page 226: ...0 12 ft lbs 14 16 Nm Page 4 13 Battery cables to terminals 60 96 in lbs 7 11 Nm Page 4 6 Enrichener stay plate 13 23 in lbs 2 3 Nm Page 4 15 Fuel cap flange to fuel tank 20 22 in lbs 2 3 Nm Page 4 10 Fuel tank to T shaped bracket 6 8 ft lbs 8 11 Nm Page 4 6 Fuel valve to fuel tank 12 14 in lbs 1 2 Nm Page 4 8 Tank cover to T shaped bracket 30 36 in lbs 3 4 Nm Page 4 6 Throttle position sensor 13 2...

Page 227: ...ent 3 Restricted fuel tank vent system 4 High speed riding style 5 Idle speed improperly adjusted 6 Loose jets 7 Fuel level too high 8 Plugged or restricted bowl vent 9 Worn or damaged needle or needle jet 10 Vacuum piston assembly malfunction 11 Plugged air jets or passages Remedy 1 Adjust clean or replace 2 Replace as required 3 Correct restricted hose Replace vapor vent valve 4 Modify riding ha...

Page 228: ...ly malfunction Remedy 1 Adjust operating idle speed 2 Correct as required 3 Correct restricted hose Replace vapor vent valve 4 Replace 5 Adjust clean or replace 6 Correct and clear restriction 7 Clean and clear passages 8 Clean clear and correct as required 9 Replace assembly 10 See Table 4 2 POOR HIGH SPEED PERFORMANCE Check for 1 Inlet system air leak 2 Enrichener valve not seated or leaking 3 R...

Page 229: ...iston binding 7 Piston vacuum passage plugged Remedy 1 Clear vent 2 Tighten or replace cap 3 Correct or replace spring 4 Reposition diaphragm lip 5 Replace piston diaphragm assembly 6 Clean piston slides and body or replace piston 7 Clean and clear passage PISTON DOES NOT CLOSE PROPERLY Check for 1 Spring damaged 2 Piston binding 3 Piston diaphragm ring dirty or damaged Remedy 1 Replace spring 2 C...

Page 230: ...ng from around threaded hole 6 Remove tank cover and set aside 7 Install oil dipstick back into threaded hole in frame back bone Fuel Tank 8 Rotate the 3 position valve handle on the fuel valve to the fully vertical position to shut the gasoline supply to the carburetor OFF See A of Figure 4 5 11WARNING 1WARNING Some gasoline will drain from the outlet hose when dis connected from the fuel valve T...

Page 231: ...n rear of seat until spring loaded latch fully engages groove of seat pin 11WARNING 1WARNING Pull up on seat to verify that it is properly secured front and rear A loose seat may shift during vehicle operation and startle the rider possibly causing loss of vehicle control that could result in death or serious injury FUEL CAP Removal 1 Locate the fuel filler cap at the top of the fuel tank 1 Insert...

Page 232: ...replace fuel filter strainer every 20 000 miles 11WARNING 1WARNING Gasoline is extremely flammable and highly explosive When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Inadequate safety precautions could result in death or serious injury 1 Remove seat Depress latch at bottom and pull seat up and back to remove See Figure 4 1 11WARNING 1WARNING To protect a...

Page 233: ... assembly into fuel tank bore and install two allen head screws Alternately tighten screws to 12 14 in lbs 1 2 Nm 4 Push hose onto outlet fitting at side of fuel valve Turn slotted screw to tighten band clamp 5 Verify that handle of fuel supply valve is in the OFF posi tion and fill the fuel tank 6 Rotate handle of fuel supply valve to ON and carefully inspect for leaks Return the valve to the OFF...

Page 234: ...f fuel supply valve to OFF Remove spare hose from outlet fitting 4 Insert finger into depression at top of fuel filler cap and lift the locking tab up Rotate tab 1 4 turn in a counter clockwise direction and then pull to remove fuel filler cap from tank 5 Carefully cut small cable strap and pull vent tube from fit ting at front of fuel cap flange 6 Alternately loosen and remove eight fuel cap flan...

Page 235: ... valve in the opposite direction A few attempts may be needed to achieve the desired result CAUTION Do not overtighten vent tube fitting or attempt to tighten with standard click type torque wrench Overtightening fitting can snap off threaded end of rollover valve possi bly causing damaged parts to fall into fuel tank 7 Using a dial type torque wrench on hex final tighten vent tube fitting to 40 6...

Page 236: ...ng Pad Fuel Tank Main Fuel Valve Bracket Rollover Valve Fuel Cap Boot O Ring O Ring Screw 8 Screw 2 vent tube Fitting Hose 1 4 I D x 1 2 O D Hose 1 4 I D x 1 2 O D a0180x4x Bolt Bracket Filter Strainer Rubber Stop 2 Warning Label Tank Cover Trim Ring Mounting Ring Screw a0179x4x TANK COVER FUEL TANK Nylon Washer NOTE Hose is sold in bulk length only Cut to required size Clip Nut ...

Page 237: ...pull out air box When partially removed detach PCV outlet hose from middle fitting on 3 way connector 10 Remove gasket from inboard side of air box Discard gasket CLEANING AND INSPECTION 1 Thoroughly clean air cleaner cover and backplate 2 Replace the filter element if damaged or if filter media cannot be adequately cleaned 11WARNING 1WARNING Do not use gasoline or solvents to clean the filter ele...

Page 238: ...k positions Alternately tighten screws to 18 22 in lbs 1 5 1 8 Nm 6 Slide spacer onto longer allen head screw gold if removed Apply a small dab of Loctite Medium Strength Threadlocker 243 blue to threads of screw and install into remaining hole in venturi ring 2 o clock position Tighten screw to 18 22 in lbs 1 5 1 8 Nm 7 Squeeze wings on spring clamp with pliers and push free end of PCV outlet hos...

Page 239: ...r Gasket Mounting Bracket Mounting Bracket Drain Plug Hose Clamp PCV Valve Venturi Ring Left Side Right Side Screw Spring Clamp Screw Screw Screw Spacer Hose Connector 3 Way Hose Connector 3 Way Hose 90o Preformed Hose 45o Preformed a0181x4x NOTE Hose not identified as preformed is sold in bulk length only Cut to required size Hose 3 8 I D x 5 8 O D ...

Page 240: ...cable bracket Using a needle nose pliers care fully pull idle cable barrel from hole in throttle wheel farthest from cam stop Pull throttle cable barrel from remaining hole in throttle wheel Release idle and throttle cables from guides in throttle cable bracket and remove carburetor from vehicle 10 Keeping carburetor upright move to bench area Without tilting carburetor or turning upside down remo...

Page 241: ...so that tongue at bot tom engages slot in frame weldment Push down on rear of seat until spring loaded latch fully engages groove of seat pin 11WARNING 1WARNING Pull up on seat to verify that it is properly secured front and rear A loose seat may shift during vehicle operation and startle the rider possibly causing loss of vehicle control that could result in death or serious injury 14 Rotate hand...

Page 242: ...e from tab on float Remove wireform clip from groove in fuel valve See upper frame of Figure 4 18 4 Using slot at top turn main jet with flat tip screwdriver to unthread from needle jet holder If necessary hold hex on needle jet holder with a 5 16 inch wrench to prevent rotation See Figure 4 17 5 Using a 5 16 inch wrench turn hex on needle jet holder to unthread from main jet bore 6 Turn carbureto...

Page 243: ...uretor throat Placing gloved finger over hole in carburetor throat blow carburetor cleaner out of main jet bore at bot tom of carburetor housing Float Bowl Vent a Spray carburetor cleaner into air inlet hole of float bowl vent See A of Figure 4 19 While spraying ver ify that solution exits two holes in float bowl chamber at bottom of carburetor housing See B of Figure 4 19 b Using a tapered rubber...

Page 244: ...1 Install vacuum piston into carburetor body Slides on pis ton are offset so piston will fit into slide track groove only one way If vacuum piston does not fit rotate assembly 180 2 Insert jet needle into vacuum piston bore so that it enters center hole at bottom In the installed position head of needle contacts boss at bottom of vacuum pis ton bore while length of shaft resides in main jet bore 3...

Page 245: ...the intake manifold side down See A of Figure 4 20 b Tilt the carburetor 15 to 20 in a counter clockwise direction until float comes to rest See B of Figure 4 20 NOTE The measurements will be incorrect if the carburetor is tilted less than 15 or more than 20 c Using a dial vernier caliper or dial caliper depth gauge measure the distance from the face of the carburetor flange to the outboard edge o...

Page 246: ...t Needle Spring Seat Band Clamp Air Intake Manifold Idle Screw Manifold Carburetor Coupler Throttle Cable Bracket Float Bowl Assembly Band Clamp Screw 2 Top Screw Collar Manifold Engine O Ring Throttle Position Sensor Band Clamp Hose Spring Fuel Valve with Clip Screw w Lockwasher Screw w Lockwasher w O Ring w O Ring and Joint Collar Seal Pin Pin Terminal Secondary Lock Attachment Clip 6 Place Deut...

Page 247: ...flange bolts from triangular shaped bracket fastened to crankcase Do not remove bottom bolt to crankcase CAUTION Do not take bolt in and out of the crankcase unless nec essary Since the potential for stripping always exists during removal and installation leave the bolt intact to avoid possible damage to the crankcase 8 Returning to the right side of the vehicle turn slotted screw to loosen band c...

Page 248: ...r is blocked and the fast idle stops See A and B above When the ignition is shut off the power to the heater is cut Deactivation of the heater causes the wax element to begin to cool During some hot warm starts the wax element may have cooled quicker than the engine which can result in a fast idle period of short duration When the wax element has cooled sufficiently the silicone gradually contract...

Page 249: ...Nm 6 Returning to the right side of the vehicle fix position of carburetor on manifold carburetor coupler Turn slotted screw to tighten band clamp on outboard side of coupler 7 Apply one drop of Loctite High Strength Threadlocker 262 red to threads of hex screw Install screw at bottom of air box 6 o clock position to secure air box bracket to crankcase hole Tighten screw to 10 12 ft lbs 14 16 Nm 8...

Page 250: ... shaped bracket fastened to crankcase Do not remove bottom bolt to crankcase CAUTION Do not take bolt in and out of the crankcase unless nec essary Since the potential for stripping always exists during removal and installation leave the bolt intact to avoid possible damage to the crankcase 8 Returning to the right side of the vehicle turn slotted screw to loosen band clamp on outboard side of man...

Page 251: ...ic or the volt age reading at WOT exceeds 3 7V see Figure 7 10 for diagnostic testing NOTE After WOT the TPS reading may not return back to exactly 0 5V 0 05V To re check exact TPS voltage reading turn cycle key off and on i Tighten TP Sensor mounting screws to 13 23 in lbs 2 3 Nm 7 Moving to opposite side of vehicle apply a small dab of Loctite Low Strength Threadlocker 222 Purple to threads of t...

Page 252: ...V outlet hose A preformed hose on one end of the fitting is fixed to an allen head screw on the venturi ring for positive location Crankcase vapors passing through the PCV valve follow the fuel vapors to the charcoal canister via a 3 way fitting plumbed into the PCV outlet hose The fuel and crank case vapors after passing through the charcoal canister travel through the purge hose to the carbureto...

Page 253: ...other TANK 4 Pull PCV outlet hose connection from carburetor throat and PCV valve from fitting at front of charcoal canister 5 Slide charcoal canister rearward until backside of tongue at top of canister just contacts two legs on bracket Hold ing canister in position use the tip of a large screwdriver to push up on outboard leg until it comes down to rest on top of tongue See Figure 4 27 Repeat pr...

Page 254: ...way connector inboard of the carburetor splits the path of the hose into two directions The center barb pointed at the left side of the vehicle is attached to the hose routed to the charcoal canister while the end barb is connected to a short hose that jumps to a second 3 way connector located inboard of the air box Charcoal Canister Hose The hose to the charcoal canister is routed from the center...

Page 255: ...s together at the back of the canis ter while another secures both tubes to the PCV outlet hose at the front of the canister NOTE On non California models the end of the tank vent tube gets routed through the slot at the front of the tail section and then into the cavity on the inboard side of the battery box alongside the transmission vent hose while the carb vent tube purge tube is absent Purge ...

Page 256: ...2002 Buell P3 Fuel System 4 31 HOME ...

Page 257: ... 2 Electric Starter System 5 2 5 3 Starter Diagnostics 5 5 5 4 Starter Activation Circuits 5 7 5 5 Diagnostics Troubleshooting 5 8 5 6 Starter System Testing 5 10 5 7 Starter 5 11 5 8 Starter Solenoid 5 19 ELECTRIC STARTER 5 Table Of Contents ...

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Page 259: ......

Page 260: ...00 amp max 2 4 V Stall Torque 8 1 ft lbs 11 0 Nm min 2 4 V SERVICE WEAR LIMITS IN MM Brush Length minimum 0 433 11 0 Commutator Diameter minimum 1 141 28 981 ITEM TORQUE NOTES Battery terminal bolts 60 96 in lbs 7 11 Nm Page 5 18 Starter battery positive cable nut 80 100 in lbs 9 11Nm Metric Page 5 18 Starter mounting bolts 13 20 ft lbs 18 27 Nm Page 5 18 5 ...

Page 261: ...5 1 When the starter switch is pushed the starter relay is activated and battery current flows into the pull in winding 10 and the hold in winding 11 to ground The magnetic forces of the pull in and hold in windings in the solenoid push the plunger 7 causing it to shift to the left This action engages the pinion gear 1 with the clutch ring gear 13 At the same time the main solenoid contacts 8 are ...

Page 262: ...ting circuit see wiring diagram Starting circuitsee wiring diagram 1 Pinion Gear 2 Idler Gear 3 Field Winding 4 Armature 5 Brush 6 Ball Bearing 7 Solenoid Plunger 8 Main Solenoid Contacts 9 Battery 10 Pull in Winding 11 Hold in Winding 12 Overrunning Clutch 13 Clutch Ring Gear Starter during cranking Starter at moment starter switch is closed ...

Page 263: ...ding grounded Replace Armature winding grounded or short cir cuited Reduction gears damaged Insufficient brush spring tension Disconnected lead wire between solenoid and field windings Repair or replace lead wire Ball bearing sticks Replace bearing Battery Voltage drop due to discharged battery Charge battery Short circuit or open between electrodes Replace battery Poor contact condition of batter...

Page 264: ...th Starter Button Pressed Check for Ground at Relay Terminal 85 Ground Present Inspect Starter Interlock Circuit or Correct Relay Ground Check for Battery Voltage to Starter Button W BK Wire Battery Voltage Present Replace Right Handlebar Switch gear NO Repair Wiring to Starter Button YES YES Repair Wiring From Starter Button to Relay NO YES YES NO NO 1 Perform Voltage Drop Tests Between Battery a...

Page 265: ...otor Free Draw Bench Test Are Test Results in Range Perform Starter Motor Current Draw Test on Vehicle STARTER STALLS OR SPINS TOO SLOWLY Disconnect Solenoid Relay Terminal from Solenoid Is 12V Present at GN Wire Terminal with Starter Button NOT Pressed Is 12V Present on Starter Relay Terminal 86 with Starter Button NOT Pressed Replace Right Handlebar Switch gear Replace Starter Relay Replace Sole...

Page 266: ...50A 20A 20A 0 1A 150A 0 1A 150A 20A 20A 0 1A 150A 0 1A 150A 20A 20A 0 1A 150A 0 1A VDC ITEM A IDEAL CLOSED CIRCUIT GROUND CIRCUIT OPEN CIRCUIT a0193x5x OV VDC VDC 12V OV ITEM B ITEM C ITEM D 1 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 1 Start Switch 2 Relay 3 Solenoid 4 Starter 5 Battery 6 Main Circuit Breaker 7 Ignition Switch 8 Ignition Circuit Breaker ...

Page 267: ...ll the voltage dropped and the entire difference in potential displayed on the meter 6 Typically a good circuit will drop less than 1 volt 7 If the voltage drop is greater back track through the con nections until the source of the potential difference is found The benefit of doing it this way is speed a Readings aren t as sensitive to real battery voltage b Readings show the actual voltage droppe...

Page 268: ...LIGHTS 61 TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 4 3 2 1 CLUTCH SWITCH 95 16 Y 16 GY 16 R 2 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B 6A RATING 6A RATING 16 R B C D A F E D C B A ON OFF PARK LOCK F E D C B A KEY SWITCH LOGIC TO BATT NEG MAIN CHASSIS GROUND 4 3 2 1 MASTER C B 123 START RELAY 87A 87 85 30 86 30A 128 START RELAY FROM TO GND BATTERY R BE BK 2 1 COLOR CODE BE BLUE BK ...

Page 269: ...ing properly proceed to STARTER CURRENT DRAW TEST Starter Current Draw Test NOTE Engine temperature should be stable and at room tem perature Battery should be fully charged See Figure 5 8 Check starter current draw with an induction ammeter before disconnecting battery Proceed as follows 1 Verify that transmission is in neutral Disconnect spark plug wires from spark plug terminals 2 Clamp inducti...

Page 270: ... support bracket and primary cover See 2 21 FOOTPEGS AND FOOTPEG SUP PORT BRACKETS 5 See Figure 5 9 Remove locknut and clamp that secure oil hoses on right side of motorcycle 6 Push hoses to either side to allow access to starter 7 See Figure 5 10 Remove both starter mounting bolts and washers NOTE A ball hex driver may be required to gain access to the starter mounting bolts 8 See Figure 5 11 Rem...

Page 271: ... be a problem with engine or primary drive Starter Solenoid NOTE Do not disassemble solenoid Before testing disconnect field wire from motor terminal as shown in Figure 5 13 CAUTION Each test should be performed for only 3 5 seconds to prevent damage to solenoid NOTE The solenoid Pull in Hold in and Return tests must be per formed together in one continuous operation Conduct all three tests one af...

Page 272: ...rly b If starter pinion does not remain in pull in position replace the solenoid Solenoid Return Test 1 See Figure 5 15 With test leads still connected in the manner specified at the end of the previous SOLENOID HOLD IN TEST disconnect solenoid relay terminal positive battery post test lead C at either end 2 Observe starter pinion a If starter pinion returns to its original position sole noid is w...

Page 273: ...than 0 016 in 0 406 mm of runout should be replaced or machined on a lathe b Replace commutators when diameter is less than 1 141 in 28 981 mm c Check armature bearings Replace if necessary CAUTION Do not use sandpaper or emery cloth to remove burrs on commutator Otherwise abrasive grit may remain on commutator segments this could lead to excessive brush wear Use only the recommended crocus cloth ...

Page 274: ...e Replace shorted armatures 10 See Figure 5 21 Check for a GROUNDED ARMATURE with an ohmmeter or continuity tester a Touch one probe to any commutator segment 1 b Touch the other probe to the armature core 2 c There should be no continuity infinite ohms If there is continuity then the armature is grounded Replace grounded armatures Figure 5 19 Undercutting Mica Separators Mica must not be left wit...

Page 275: ... to the field wire 1 b Touch the other probe to each of the brushes attached to the field coil s 2 c There should be continuity 0 ohms If there is no continuity at either brush then the field coil s are open and the field frame must be replaced 14 See Figure 5 25 Test BRUSH HOLDER INSULATION with an ohmmeter or continuity tester a Touch one probe to holder plate 1 b Touch the other probe to each o...

Page 276: ...over 3 with end cover screws and O rings 2 7 Install thru bolts 1 8 Attach field wire 22 to solenoid housing 11 with field wire nut and washer 24 metric Replace rubber boot Figure 5 26 Starter Drive Assembly 4 O ring 5 Drive Housing 6 Screws 1 Drive 2 Idler Gear 3 Idler Gear Bearing 1 2 3 4 5 6017 6 Figure 5 27 Starter Assembly 1 Thru Bolt 2 2 End Cover Screw and O ring 2 3 End Cover 4 Brush Holde...

Page 277: ...RY CHAIN 6 Fill transmission to proper level with fresh lubricant See 1 10 TRANSMISSION PRIMARY FLUID 7 Install left side footrest support assembly See 2 21 FOOTPEGS AND FOOTPEG SUPPORT BRACKETS 8 Install air cleaner See 4 3 AIR CLEANER 1WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks co...

Page 278: ...nd a hollow cylinder con taining a movable plunger DISASSEMBLY 1 See Figure 5 30 Remove screws 1 and clip 2 2 Remove cover 3 and gasket 4 Discard gasket 3 Remove plunger 5 from solenoid housing 6 ASSEMBLY 1 See Figure 5 30 Replace wire connection hardware as necessary 2 Install plunger 5 in solenoid housing 6 3 Install new gasket 4 onto cover 3 4 Position cover with gasket onto solenoid housing In...

Page 279: ...5 20 2002 Buell P3 Electric Starter HOME NOTES ...

Page 280: ...4 6 7 Transmission 6 21 6 8 Transmission Case 6 22 6 9 Transmission Disassembly 6 24 6 10 Transmission Assembly 6 29 6 11 Main Drive Gear 6 33 6 12 Right Transmission Case Bearings 6 35 6 13 Left Crankcase Bearings 6 37 6 14 Transmission Installation 6 39 6 15 Shifter Pawl Adjustment 6 41 6 16 Transmission Sprocket 6 43 DRIVE TRANSMISSION 6 Table Of Contents ...

Page 281: ......

Page 282: ... 1 N A Transmission Primary drive transmission lubricant capacity 32 fl oz 946 ml N A Overall gear ratios First gear low 12 74 N A Second gear 8 77 N A Third gear 6 79 N A Fourth gear 5 60 N A Fifth gear high 4 74 N A Internal gear ratios indicate number of mainshaft revolutions required to drive output sprocket one revolution Overall gear ratios indicate number of engine revolutions required to d...

Page 283: ... ft lbs 258 285 Nm LOCTITE thread locker 262 red Page 6 20 Primary cover bolts 100 120 in lbs 11 14 Nm Follow torque sequence Page 6 6 Rear axel nut 48 52 ft lbs 65 71 Nm Page 6 9 Retention collar screw 13 17 ft lbs 18 23 Nm LOCTITE thread locker 243 blue Page 6 41 Shift lever pinch fastener 12 14 ft lbs 16 19 Nm Page 6 6 Shifter shaft assembly locknuts 90 110 in lbs 10 12 Nm Bottom nut first same...

Page 284: ...es become worn it must be replaced Remove and install the chain fol lowing the procedure under 6 6 PRIMARY DRIVE CLUTCH Figure 6 1 Primary Cover and Shifter Assembly 1 TORX Screw with Washers 3 2 Clutch Inspection Cover 3 Clutch Cover Gasket 4 Spring 5 Lockplate 6 Nut 7 Ramp Assembly 8 Primary Cover 9 Bushing 10 Spring 11 Chain Guide 12 Gasket 2 3 4 5 6 7 10 12 18 a0104x6x 8 9 11 24 13 Pin 14 Shoe...

Page 285: ...iscard gasket from groove in primary cover 10 Slide spring with attached hex lockplate from flats of clutch limiting screw 11 Turn clutch adjusting screw clockwise to release ramp and coupling mechanism As the limiting screw is turned ramp assembly moves forward Unscrew nut from end of limiting screw 12 Remove hook of ramp from button to the rear of cable end coupling Remove cable end from slot in...

Page 286: ...ing screw and the locknut The spacer is used to quickly get proper adjustment during production This spacer should be removed and discarded at the first adjustment interval 1 See Figure 6 5 Back off locknut and chain limiting screw Remove spacer IMPORTANT NOTE Be certain to use Inch Pound Wrench Chain adjuster shoe can be damaged by excessive force 2 See Figure 6 6 Tighten chain limiting screw to ...

Page 287: ...til slot of screw is accessible with a screwdriver Fit nut hex into recess of outer ramp and turn adjustment screw counterclockwise 7 Adjust clutch See ADJUSTMENT under 6 5 CLUTCH RELEASE MECHANISM 8 Adjust primary chain tension See 6 2 PRIMARY CHAIN 9 Fill transmission to proper level with fresh lubricant See TRANSMISSION FLUID under section 6 4 CLUTCH 10 Install clutch inspection cover with new ...

Page 288: ...ling is common but it indicates that sprockets are misaligned Outside ribbed surface for signs of stone puncture 7 If cracks damage exists near edge of belt replace belt immediately Damage to center of belt will require belt replacement eventually but when cracks extend to edge of belt belt failure is imminent Inside toothed portion of belt for exposed tensile cords normally covered by nylon layer...

Page 289: ...ion 2 External tooth cracks Replace belt 3 Missing teeth Replace belt 4 Chipping not serious OK to run but monitor condition 5 Fuzzy edge cord OK to run but monitor condition 6 Hook wear Replace belt 7 Stone damage Replace belt if damage is on the edge 8 Bevel wear outboard edge only OK to run but monitor condition 1 2 3 4 5 6 7 8 Stone Cross section shown a0147x6x Sprocket side of belt ...

Page 290: ...See 2 21 FOOTPEGS AND FOOTPEG SUPPORT BRACKETS 13 Remove three TORX bolts washers and front sprocket cover from right side of motorcycle 14 Remove two TORX screws and washers from right side of rear inner fender 15 Carefully bend rear inner fender upwards and remove drive belt Discard drive belt INSTALLATION 1 Install a new drive belt over transmission drive sprocket 2 Install rear inner fender wi...

Page 291: ...ry cable from battery 6 Remove left footpeg support bracket See 2 21 FOOT PEGS AND FOOTPEG SUPPORT BRACKETS 7 Remove three TORX screws with washers 1 from clutch inspection cover 2 Remove clutch inspection cover from primary cover CAUTION Do not overfill the primary chaincase with lubricant Overfilling may cause rough clutch engagement incom plete disengagement clutch drag and or difficulty in fin...

Page 292: ...tall lock plate 5 and spring 4 on adjusting screw flats If hex on lockplate does not align with recess in outer ramp rotate adjusting screw clockwise until it aligns 7 Squeeze clutch hand lever to maximum limit three times This sets the ball and ramp mechanism Pull outer cable conduit and at the same time adjust cable adjuster to provide 0 0625 0 125 in 1 6 3 2 mm freeplay at clutch hand lever Adj...

Page 293: ...ew 7 Turn adjusting screw clockwise to release ramp and cou pling mechanism As the adjusting screw is turned ramp assembly moves forward Unscrew nut from end of adjusting screw CLEANING AND INSPECTION 1 Thoroughly clean all parts in cleaning solvent 2 See Figure 6 16 Inspect three balls of release mecha nism and ball socket surfaces of inner and outer ramps for wear pitting surface breakdown and o...

Page 294: ... until slot of screw is accessible with a screwdriver b Turn adjusting screw counterclockwise until resis tance is felt c Adjust clutch release mechanism See 6 4 CLUTCH d Fit nut hex into recess of outer ramp 11WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sio...

Page 295: ...rom the engine will be transmitted to the rear wheel When the clutch is disengaged clutch lever pulled to left han dlebar grip the pressure plate is pulled outward by clutch cable action against the diaphragm spring thereby com pressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch plates together The fiber plates are now free to rotate at...

Page 296: ...spring c Install bearing and washer d Thread the tool handle onto end of forcing screw CAUTION See Figure 6 21 Turn compressing tool handle only the amount required to release spring seat and remove snap ring Excessive compression of diaphragm spring could damage clutch pressure plate 3 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw flats to prevent the forcing ...

Page 297: ...ring 12 Retaining Ring 13 Release Plate 14 Retaining Ring 15 Bearing 16 Adjusting Screw 17 Pressure Plate 18 Friction Plate paper 5 19 Steel Plate 5 20 Mainshaft Nut 21 Washer 22 Clutch Hub 23 Retaining Ring 24 Bearing 25 Clutch Shell and Sprocket 26 Retaining Ring 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 Spring 2 Lockplate 3 Nut 18 19 20 21 22 23 24 25 26 Labeled OUT a0114x6x ...

Page 298: ... screw assembly into pressure plate a See Figure 6 24 Align two tabs on perimeter of release plate with corresponding recesses in pres sure plate b See Figure 6 23 Secure the adjusting screw assembly with large retaining ring 8 Attach tools to compress clutch diaphragm spring See Step 2 of CLUTCH PACK under 6 6 PRIMARY DRIVE CLUTCH 9 Remove clutch pack components See Steps 3 4 of CLUTCH PACK under...

Page 299: ...ed more than 0 006 in 0 152 mm 2 Check the diaphragm spring for cracks or bent tabs Install a new spring if either condition exists 3 See Figure 6 25 Check fiber plates for thickness a Wipe the lubricant from the five fiber plates and stack them on top of each other b Measure the thickness of the five stacked fiber plates with a dial caliper or micrometer The mini mum thickness must be 0 413 in 10...

Page 300: ...board side of spring seat and fully seated in groove of clutch hub carefully loosen and remove compression tool Primary Drive 1 See Figure 6 28 Assemble clutch hub and shell if nec essary a Press new bearing in clutch shell Secure bearing with a new retaining ring b Press inboard end of clutch hub into shell bearing Secure with new retaining ring on end of hub 2 Assemble pressure plate hardware a ...

Page 301: ...E thread locker 262 red onto threads on end of mainshaft b Place washer on mainshaft with the word out fac ing away from clutch hub c Install nut left hand threads Tighten to 70 80 ft lbs 95 109 Nm 4 Remove SPROCKET LOCKING LINK 5 Install adjusting screw assembly into pressure plate a See Figure 6 24 Align two tabs on perimeter of release plate with corresponding recesses in pres sure plate b See ...

Page 302: ...nsmission and refill to correct level with fresh clean lubricant at least once each year or every 5000 miles 8000 km whichever comes first For best results drain lubricant while hot See 6 4 CLUTCH Figure 6 31 Transmission Power Flow 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 Neutral Power flow Sliding member Countershaft Mainshaft Out 1st Gear Countershaft Mainshaft In 2nd Gear Co...

Page 303: ...Remove countershaft TORX screw 1 and retention collar 2 9 See Figure 6 33 Detach spring 11 from groove in post 10 Remove retaining ring 10 and detent plate 9 Discard retaining ring 10 You will need to use a new retaining ring for installation 11 Remove starter See 5 7 STARTER 12 Remove two locknuts 2 and washers 3 which attach shifter shaft assembly 1 to studs at transmission case Remove shifter s...

Page 304: ... 1 2 in long 5 3 Washer 21 64 x 9 16 x 19 14 4 Hex Socket Head Screw 3 8 16 X 4 1 2 in long 1 5 Spacer 1 6 Washer 3 8 I D X 13 16 O D 1 7 Nyloc Hex Locknut 3 8 16 8 Hex Socket Head Screw 5 16 18 X 2 1 2 in long 9 9 Rear Isolator 10 Screw 4 11 Washer 4 1 a0103x3x 7 8 3 8 3 8 3 8 3 8 3 8 3 2 3 2 3 2 3 2 3 2 3 8 3 8 3 9 10 11 6 4 5 ...

Page 305: ... 8 TRANSMISSION CASE 3 Remove crankcase and transmission assembly from engine stand 4 See Figure 6 37 Place crankcase 3 and transmission assembly 4 into fixture on arbor press 1 a Support transmission assembly on parallel supports 5 5 Press transmission assembly using TRANSMISSION REMOVER 2 Part No B 43895 1 to remove transmis sion assembly from crankcase half 6 Remove crankcase from fixture Figur...

Page 306: ... in the other direction 4 Remove shifter forks 16 17 18 Figure 6 38 Shifter Mechanism 1 Right Crankcase Half 2 Mainshaft Bearing 3 Countershaft Bearing 4 Plate 5 Pin 6 Detent Arm 7 Detent Screw 8 Detent Plate 9 Retaining Ring 10 Shifter Shaft Assembly 11 Locknut 2 12 Washer 2 13 Shifter Pawl 14 Cotter Pin 3 15 Shifter Fork Pin 3 16 Shifter Fork 4th Gear 17 Shifter Fork 1st 2nd Gear 18 Shifter Fork...

Page 307: ...facing its original direction 1 See Figure 6 39 As each component is removed place it on a clean surface in the exact order of removal Figure 6 39 3559 Figure 6 40 Transmission Assembly Right Crankcase Half 1 Bearing Inner 2 Fifth Gear Mainshaft 3 Bearing Outer 4 Oil Seal 5 Right Crankcase Half 6 Ball Bearing 7 Retaining Ring 8 Quad Seal 9 Spacer 10 Oil Seal 11 Bearing closed end Shifter Drum 12 B...

Page 308: ...st Washer 6 11 Retaining Ring 7 12 First Gear Mainshaft 13 Third Gear Mainshaft 14 Second Gear Mainshaft 15 Spacer 16 Fourth Gear Countershaft 17 First Gear Countershaft 18 Countershaft 19 Third Gear Countershaft 20 Second Gear Countershaft 21 Fifth Gear Countershaft 22 Bearing 23 Retaining Ring 24 Countershaft Retainer 25 Screw a0126x6x 16 15 5 4 3 2 1 22 23 24 25 11 10 11 21 20 8 10 11 19 18 11 ...

Page 309: ... 11 next to countershaft 5th gear 21 Slide countershaft 5th 21 and countershaft 2nd 20 off end of countershaft 18 2 Remove split bearing 8 that was under countershaft 2nd gear 20 and thrust washer 10 including retaining ring 11 on the countershaft 6 Slide countershaft 3rd 19 gear off free end of shaft 18 3 Remove beveled washer spacer 15 and countershaft 4th gear 16 4 Expand retaining ring 11 loca...

Page 310: ...2nd gear 14 onto shaft with the fork groove facing 3rd gear 13 COUNTERSHAFT SUB ASSEMBLY 1 See Figure 6 42 Install new retaining ring 11 and thrust washer 10 onto countershaft 18 in the second ring groove from the end 2 Install split bearing 8 onto countershaft 3 Locate countershaft 1st gear 17 which can be identi fied by the two radial grooves at one side Slide gear 17 onto shaft Position gear ov...

Page 311: ...st Washer 6 11 Retaining Ring 7 12 First Gear Mainshaft 13 Third Gear Mainshaft 14 Second Gear Mainshaft 15 Spacer 16 Fourth Gear Countershaft 17 First Gear Countershaft 18 Countershaft 19 Third Gear Countershaft 20 Second Gear Countershaft 21 Fifth Gear Countershaft 22 Bearing 23 Retaining Ring 24 Countershaft Retainer 25 Screw a0126x6x 16 15 5 4 3 2 1 22 23 24 25 11 10 11 21 20 8 10 11 19 18 11 ...

Page 312: ...ft is then in the neutral position CAUTION To prevent possible cotter pin damage the pins must be inserted through the shifter forks as shown in the inset of Figure 6 44 5 Align the hole through the top of each shifter fork with the appropriate cam groove in the shifter drum Lubricate pins with Sport Transmission Lube Drop pins through the holes in shifter forks With a small screwdriver press on t...

Page 313: ... Screw 8 Detent Plate 9 Retaining Ring 10 Shifter Shaft Assembly 11 Locknut 2 12 Washer 2 13 Shifter Pawl 14 Cotter Pin 3 15 Shifter Fork Pin 3 16 Shifter Fork 4th Gear 17 Shifter Fork 1st 2nd Gear 18 Shifter Fork 3rd 5th Gear 19 Shifter Fork Drum 20 Neutral Indicator Pin 1 13 12 11 10 4 5 6 7 8 9 a0118x6x 2 3 14 14 14 15 15 14 15 16 17 18 19 20 Insert cotter pins as shown ...

Page 314: ... removing the main drive gear the gear is pressed out against the resistance of the bearing inner race Without any support at the inner race the bearing is destroyed Whenever the main drive gear is removed the main drive gear bearing will also have to be replaced 9 At outside of case place driver 4 and thrust washer 5 over end of bolt 2 Install and tighten nut 6 until 5th gear 3 is free Figure 6 4...

Page 315: ...39 mm c Press in the inner bearing to a depth of 0 080 in 2 032 mm INSTALLATION 1 Replace main drive gear bearing 2 See Figure 6 49 Use MAIN DRIVE GEAR REMOVER AND INSTALLER Part No HD 35316 A for assembly a Take bolt 2 and place washer 5 followed by main drive gear 4 over end of bolt b From inside of case insert bolt and main drive gear through inner race of ball bearing c Insert threaded end of ...

Page 316: ...ly Tighten nut 6 until bearing is seated against shoulder in bore 3 At outside of case install beveled retaining ring in groove inside bearing bore with beveled side facing outside of case 4 Lubricate bearing with SPORT TRANS FLUID Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in diameter 2 From the outside of the case place the needle bearing open end first next t...

Page 317: ...Right Crankcase Half 1 Bearing 2 2 Fifth Gear Mainshaft 3 Needle Bearing 2 4 Oil Seal 5 Right Crankcase Half 6 Ball Bearing 7 Retaining Ring 8 Quad Seal 9 Spacer 10 Oil Seal 11 Bearing closed end Shifter Drum 12 Bearing closed end Countershaft a0127x6x 5 9 8 7 6 4 3 2 1 10 11 12 ...

Page 318: ...aft Bearings 1 Place crankcase on press with inside surface of crank case downward 2 Lay bearing squarely over bore with printed side of bear ing upward Place section of pipe or tubing slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder 3 Install new retaining ring with beveled side facing away from bearing Shift Drum ...

Page 319: ...st Washer 6 11 Retaining Ring 7 12 First Gear Mainshaft 13 Third Gear Mainshaft 14 Second Gear Mainshaft 15 Spacer 16 Fourth Gear Countershaft 17 First Gear Countershaft 18 Countershaft 19 Third Gear Countershaft 20 Second Gear Countershaft 21 Fifth Gear Countershaft 22 Bearing 23 Retaining Ring 24 Countershaft Retainer 25 Screw a0126x6x 16 15 5 4 3 2 1 22 23 24 25 11 10 11 21 20 8 10 11 19 18 11 ...

Page 320: ...b See Figure 6 57 Install TRANSMISSION INSTALLER Part no B 43985 3 into crankcase 3 See Figure 6 57 Press crankcase into transmission assembly until it bottoms out 4 Remove transmission assembly and left crankcase half from fixture 5 See Figure 6 58 Assemble crankcase halves together a Apply a thin coat of DOW CORNING SILASTIC or 3 M 800 sealant to crankcase joint faces b See CRANKCASE HALVES Atta...

Page 321: ... in long 5 3 Washer 21 64 x 9 16 x 19 14 4 Hex Socket Head Screw 3 8 16 X 4 1 2 in long 1 5 Spacer 1 6 Washer 3 8 I D X 13 16 O D 1 7 Nyloc Hex Locknut 3 8 16 8 Bottom Case T40 TORX Bolt 5 16 18 X 3 1 2 in long 9 9 Rear Isolator 10 Screw 4 11 Washer 4 1 6 a0103x3x 4 7 5 8 3 8 3 8 3 8 3 8 3 8 3 2 3 2 3 2 3 2 3 2 3 8 3 8 3 9 10 11 ...

Page 322: ... the same torque e Remove drill bit 6 See Figure 6 52 Place new quad ring over threaded end of fifth gear and position next to the gear taper Install spacer over threaded end of fifth gear with chamfered end toward quad ring Slide spacer up against bearing 7 Install seal a Coat lips of seal with SPORT TRANS FLUID b Position seal over spacer with lips of seal toward case c Use MAIN DRIVE GEAR SEAL ...

Page 323: ...6 42 2002 Buell P3 Drive Transmission HOME Figure 6 62 Countershaft Retainer 7691 1 TORX Screw 2 Retention Collar 3 Detent Roller Arm 4 Spring 3 1 2 4 ...

Page 324: ...he line on the transmis sion sprocket as shown d Tighten the transmission sprocket nut an additional 30 40 e See Figure 6 63 Install lockplate over nut so that two of lockplate s four drilled holes diagonally oppo site align with sprocket s two tapped holes NOTE The lockplate has four screw holes and can be turned to either side so you should be able to find a position without having to additional...

Page 325: ...ation cycles the original screws may be reused up to three times After the third removal installation cycle replace both screws with new screws identical to the original 6 Install the remaining removed components in the reverse order of the removal procedures See the procedures listed in the respective component sections 7 Fill transmission to proper level with fresh lubricant See 6 4 CLUTCH Figur...

Page 326: ...gnition Interlock 7 26 7 12 Diodes 7 33 7 13 Charging System 7 34 7 14 Alternator 7 40 7 15 Voltage Regulator 7 42 7 16 Battery 7 43 7 17 Headlamp 7 47 7 18 Tail Lamp 7 50 7 19 Turn Signals 7 51 7 20 Turn Signal Flasher 7 53 7 21 Handlebar Switches 7 54 7 22 Horn 7 56 7 23 Neutral Indicator Switch 7 57 7 24 Fuses And Circuit Breakers 7 58 7 25 Electronic Speedometer 7 59 7 26 Speedometer Sensor 7 ...

Page 327: ......

Page 328: ... 4V Rev Limit 6500 RPM IGNITION COIL RESISTANCE Primary Winding 0 4 0 6 ohms Secondary Winding 7 720 9 440 ohms SPARK PLUG CABLE RESISTANCE Spark Plug Cable 2 375 5 833 ohms ELECTRICAL SYSTEM AMPERES Main Circuit Breaker 30 Ignition Fuse 7 5 Light Fuse 15 Accessory Fuse 7 5 System Fuse 15 Key Switch Fuse 15 LAMP DESCRIPTION BULBS REQUIRED WATTS AMPS PART NUMBER Headlamp High Low 1 60 55 5 0 4 58 6...

Page 329: ...or switch 3 5 ft lbs 4 7 Nm LOCTITE THREADLOCKER 243 blue Page 7 57 Rotor cup mounting fasteners 43 53 in lbs 5 6 Nm Page 7 20 Rotor mounting bolts 90 110 in lbs 10 12 Nm LOCTITE THREADLOCKER 242 blue Page 7 41 Sidestand switch fasteners 30 36 in lbs 3 4 Nm Page 7 28 Spark plug 11 18 ft lbs 15 24 Nm Page 7 3 Speedometer sensor screw 80 100 in lbs 9 11 Nm Page 7 61 Stator mounting screws 30 40 in l...

Page 330: ... in the gear case cover The module has two functions First it computes the spark advance for proper ignition timing Second it opens and closes the low voltage circuits between the battery and igni tion coil to produce high voltage discharge to the spark plug The ignition module on the P3 Blast also contains an inte grated cam position sensor Above 6500 rpm the ignition module will automatically re...

Page 331: ...the right side of the motorcycle The rotor is mounted on the camshaft and operates at one half crank shaft speed As the rotor turns a slot in its outside diameter breaks the magnetic field of a Hall effect device mounted on the cam position sensor The output of the Hall effect device is a logic type signal that corresponds to the timing informa tion from the spinning rotor This technique gives acc...

Page 332: ... MASTER C B 1 2 3 4 MAIN C HASSIS G ROUND TO BATT NEG GY 1 2 3 4 5 6 AUTO ENRIC H THROTT LE POSITION SENSOR KB LBE Y 15A 7 5A 7 5A 7 5A 95 CL UTC H SWITC H 10 83 PK IGN MODULE GN BK W R W BK W BK R W BK PK W BK V W KB BK TN Y V O FROM 3 R R R B 1 R 1 R 1 R G Y GY V O O WV WV KB S14 22 TN Y R B 1 R R O SWITC H NEUTRAL 131 TN R 2 R 2 R BK BK TN GN BK R BK R IGN POWER BE R BK1 TN TN W R 2 TN GN R BK ...

Page 333: ...1 5001 Measure Voltage At Con nector 22A Pin 4 GY Battery Voltage Present NO Repair Open GY Wire Between 22 and Fuse YES 5002 With Connector 22 Mated And Ignition On Measure Voltage At Connector 22A Pins 2 and 3 W BK Battery Voltage Present NO Repair Replace Engine Stop Switch or Wiring YES Repair Open W BK Wire Between Coil and 22A 5002 5173 PK PK W BK W BK Go To Next Page NO DESCRIPTION TYPE LOC...

Page 334: ...o BK Pin 6 On 10B Multimeter Should Register 12VDC 1 0 VDC 10 1 2 3 4 5 6 YES Check Continuity Between Pin 1 W BK 10B And Coil W BK Wire Continuity Present NO YES Repair Open In W BK Wire NO Repair Open Between 10B Pin 6 BK And Ground 5003 5003 Go To Next Page YES Perform Coil Resis tance Check If Capaci tor Is Not Available NO Check resistance between terminals A and B on coil 83A Resistance shou...

Page 335: ...Remove Timer Cover See Igni tion Module Cam Position Sensor for procedure Crank Engine Is LED Flashing NO Is Rotor Cup Rotating Replace Ignition Module YES YES NO Replace Ignition Module Remove Gearcase Cover Inspect For Mechanical Failure Repair 5009 5009 5005 Harness Adapters HD 42962 NOTE Male connectors are labeled A Female connectors are labeled B 3 3 Inspect ignition module for signs of phys...

Page 336: ...t 5 LT GN GY On Connector 10B Continuity Present YES NO See Starter Interlock Section 7 11 Check Continuity To Ground On LT GN GY Wire Socket A Connector 134B Or 10B Is Continuity Present 5007 Check Continuity To Ground On TN Y Wire Socket B Connector 134B Is Continuity Present YES NO Inspect Module Harness For Damage Repair If Neces sary If Harness Is Not Damaged Replace Ignition Module 5009 Repa...

Page 337: ... Socket C GY And Socket B BK Is Voltage 11 13 VDC NO Is Bank Angle Sen sor Correctly Installed Repair Open In GY Wire Between Bank Angle Sensor And Ignition Fuse Are Ferrous Metals Located Within 1 4 Of Sides Face Or Top Of Bank Angle Sensor YES NO Install Properly Return To Origi nal Configuration NO Replace Bank Angle Sensor YES 5007 5013 ...

Page 338: ...ocedure NOTE Male connectors are labeled A Female connectors are labeled B 1 1 Remove seat and fuel tank cover See 2 31 SEAT to ground to voltage 7553 7605 7575 7595 7554 7610 7580 7590 Check resistance Between Pin 3 and ground Is resistance less than 1 ohm YES Replace Ignition Module NO 7604 Is Timing Set Correctly YES Check Auto Enrichener See Section 7 6 NO Adjust Timing 7553 Recalibrate TP Sen...

Page 339: ...daptors HD 42962 and Breakout Box HD 42682 using black connectors between connector halves 88A and 88B f Turn ignition switch to ON Using a multimeter mea sure voltage between pin 3 V W and pin 5 BK g Adjust rotate throttle position sensor TPS until voltage reading is 0 5V 0 05V h Completely open and close the throttle by rotating the throttle control through its full range of motion Wide Open Thr...

Page 340: ... Bank Angle Sensor 7 Remove Bank Angle Sensor INSTALLATION 1 Connect connector 134 to new Bank Angle Sensor 2 See Figure 7 12 Position Bank Angle Sensor in mount ing position on circuit breaker bracket mounting screw Make sure sensor locating post engages hole in trunk to ensure proper alignment of sensor 3 Install Bank Angle Sensor with allen screw and locknut Tighten screw to 25 27 in lbs 2 8 3 ...

Page 341: ...the lights on When the key is placed in the PARK position several indi cator markers are or can be activated See the table to the right REMOVAL 1 Remove seat See 2 28 SEAT 11WARNING 1WARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before proced ing Inadequate safety precautions could result in death or serious injury 2 Disconnect negative ...

Page 342: ...sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control of vehicle and result in death or serious injury 8 Install seat See 2 28 SEAT 11WARNING 1WARNING Check for proper headlamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper headlamp operation could result in de...

Page 343: ...ot restart If enrichment cycle exceeds 5 minutes see diagnostic chart on following page See 4 5 AUTO ENRICHENER for information on replacing the auto enrichener See diagnostic chart on next page for troubleshooting infor mation NOTE Auto Enrichener wire colors may vary from those listed in Fig ure 7 15 Figure 7 15 TP Sensor Auto Enrichener Connector 88 AUTO ENRICHENER TP SENSOR CONNECTOR 88 CHAMBE...

Page 344: ... carburetor Check continuity from pin 1 on connector 88 to pin 3 on connector 10B Is continuity present at both terminals of system fuse Locate and repair open on Orange wire between system fuse and connector 88 Neither Terminal Locate and repair open on 1 Use black male probe 1 adaptor kit HD 41404 and patch cord from harness YES NO Violet Orange wire Locate and repair short to voltage Module YES...

Page 345: ...oses on right side of motorcycle 4 See Figure 7 17 Disconnect connector 10 located on the left side of the frame backbone 5 Note position of each wiring terminal in plug end of con nector 6 Remove connector terminal pins See B 2 DEUTSCH ELECTRICAL CONNECTORS 11WARNING 1WARNING Always wear proper eye protection when drilling Flying debris could result in serious eye injury CAUTION Drilling hole in ...

Page 346: ...ark Plug Cable Rotor Cup Integrated Ignition Module with Cam Position Sensor Module Plate Ignition Coil Timer Cover Throttle Position Sensor TP Sensor Connector 10 Connector 88 Auto Enrichener Module Plate Screws 2 15 30 in lbs 1 7 3 4 Nm 43 53 in lbs 4 9 6 0 Nm Screw Tamper Resistant T20 TORX Screws 13 23 in lbs 1 5 2 6 Nm Connector 83A ...

Page 347: ...2 DEUTSCH ELECTRICAL CONNECTORS 5 See Figure 7 17 Mate connector 10 and install to T stud on frame backbone 6 Install locknut to clamp that secures hoses and wire har ness on right side of motorcycle 7 Install module plate with two screws Do not tighten screws 8 Install negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 7 11 Nm 9 Check ignition timing See IGNITION TIMING 1...

Page 348: ...ck and engine failure 6 See Figure 7 21 Timing light will flash each time an ignition system spark occurs Aim timing light into timing inspection hole The advance timing mark two dots should be centered in timing inspection hole If this is the case ignition timing is properly adjusted Go to Step 11 If timing mark is not centered or is not visible in the timing inspection hole see to Steps 7 12 7 S...

Page 349: ...e air will be expelled from hole When air is no longer expelled from hole both valves are closed and engine should be close to TDC and between compression and power stroke 6 Shift transmission into fifth gear and standing on left side of vehicle slowly rotate rear wheel in direction of forward motion counter clockwise until front intake valve opens and closes 7 See Figure 7 22 Rotate rear wheel fr...

Page 350: ...TROUBLESHOOTING Follow the troubleshooting procedures listed under 7 8 IGNI TION MODULE CAM POSITION SENSOR if the engine will not start is difficult to start or runs roughly Also check condi tion of the spark plug cable Insulation on cable may be cracked or damaged allowing high tension current to short to metal parts This problem is most noticeable when cable is wet If poor starting running cond...

Page 351: ...able from coil plug post 6 See Figure 7 27 Disconnect coil connector 83 7 Remove two screws and washers and coil INSTALLATION 1 See Figure 7 24 Apply LOCTITE THREADLOCKER 243 Blue to threads of two mounting screws 2 Attach coil to frame with screws and washers 1 Tighten to 4 6 ft lbs 5 8 Nm 3 Attach coil connector 83 4 Connect spark plug cable to ignition coil 5 Attach left fascia 6 Install negati...

Page 352: ...ortion itself Pulling on the cable will damage the cable s carbon core Disconnect spark plug cable from ignition coil and spark plug terminal Inspect removed cable for damage INSPECTION 1 See Figure 7 28 Inspect spark plug cable Replace cable if worn or damaged a Check for cracks or loose terminals b Check for loose fit on ignition coil and spark plug 2 Check cable boot cap for cracks or tears Rep...

Page 353: ...hed three ways By retracting the side stand and grounding through the side stand switch See Ignition Test 1 on following page to check sidestand switch function By placing the motorcycle in neutral and grounding through the neutral switch See Ignition Test 2 on fol lowing page to check neutral switch function By disengaging the clutch and grounding through the clutch lever switch See Ignition Test...

Page 354: ...n TN W wire at connector 60 NO NO YES System OK NO Repair Wiring YES Repair open TN W wire or TN Y wire between connector 60 and Diode 2 NO Replace Sidestand Switch 5053 5054 5055 1 Use harness connector adaptor kit HD 41404 gray male probe and patch cord 1 YES YES Check Diode 1 with ohmmeter Diode OK Remove sprocket cover Check for ground at neutral switch terminal Ground present Check for ground...

Page 355: ...bs 3 4 Nm Clutch Switch See Figure 7 34 The clutch switch attaches to the clutch con trol lever bracket The switch completes a path to ground for the ignition relay and the starter relay when the clutch is dis engaged Test the switch as follows 1 Unplug the 2 place clutch switch connector 95 Figure 7 32 Ignition Test 3 YES YES Check for ground on TN GN wire of clutch switch connector 95 Ground pre...

Page 356: ...TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 4 3 2 1 CLUTCH SWITCH 95 16 Y 16 GY 16 R 2 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B 6A RATING 6A RATING 16 R B C D A F E D C B A ON OFF PARK LOCK F E D C B A KEY SWITCH LOGIC TO BATT NEG MAIN CHASSIS GROUND 4 3 2 1 MASTER C B 123 START RELAY 87A 87 85 30 86 30A 128 START RELAY FROM TO GND BATTERY R BE BK 2 1 COLOR CODE BE BLUE BK BLACK BN B...

Page 357: ...emove small Phillips screw b Depress clutch lever and hold c Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar d Install new switch NOTE To test replace the neutral switch see 7 23 NEUTRAL INDI CATOR SWITCH Figure 7 33 Side Stand Switch Figure 7 34 Clutch Switch a0230x7x Connector 60 Sidestand Switch Screw 2 30 36 in lbs 3 3 4 1 Nm Nut 2 a0231x7x...

Page 358: ...ircuit breaker studs Tag wire leads for ease of assembly 4 See Figure 7 36 Remove circuit breaker from circuit breaker bracket by carefully prying tab located on left side open and sliding circuit breaker out NOTE Bank Angle Sensor will require reinstallation if bracket is removed See 7 5 BANK ANGLE SENSOR 5 Install in the reverse order Tighten screw if bracket was removed to 25 27 in lbs 2 8 3 1 ...

Page 359: ...numbers below correlate with the circled num bers in the 7 11 STARTER IGNITION INTERLOCK flow charts 1 Check diode with an ohmmeter as shown in Figure 7 39 2 Check diode polarity as shown in Figure 7 40 3 Replace diodes as necessary Figure 7 39 Ohmmeter Diode Test Figure 7 40 Diode Polarity Continuity Infinite ohms a0235x7x a0236x7x TN TN Y Diode 1 polarity TN GN TN Y Diode 2 polarity TN W ...

Page 360: ...diode by pulling it straight up off the relay block INSTALLATION 1 See Figure 7 42 Install the new diodes into position on the fuse block by pushing it into the slot 2 Connect negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 7 11 Nm 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift du...

Page 361: ...ails to charge or does not charge at a satisfactory rate make the following recommended checks Battery Check for a weak or dead battery See 7 16 BATTERY Bat tery must be fully charged in order to perform any electrical tests Wiring Check for corroded or loose connections in the charging cir cuit See Figure 7 45 Voltage Regulator Inspection See Figure 7 43 The voltage regulator base must have a cle...

Page 362: ...pare with TOTAL CURRENT DRAW TEST before proceeding Inspect rotor Replace stator Perform AC OUTPUT TEST Replace regulator Perform VOLTAGE OUTPUT TEST Damaged or slipping rotor Perform CURRENT OUTPUT TEST System tests good up to this point Suspect 1 Accessories on for long periods when vehicle is parked and not running 2 Accessories on when vehicle is ridden very slowly for long periods 3 Battery s...

Page 363: ...128 BK 2 BK BK COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLOW LT LIGHT DIODE NO CONNECTION PIN CONNECTOR SOCKET CONNECTOR SPLICE CONNECTION CONNECTOR CODE a0278x7x Voltage Regulator Stator Battery Main Circuit Main Chassis Ground Starter Breaker ...

Page 364: ...xcessive current draw Any accessories must be considered and checked for excessive drain NOTE A battery with a surface discharge condition could suffer a static drain Correct by cleaning battery case Total Current Draw Test If battery runs down during use the current draw of the motorcycle components and accessories may exceed output of the charging system 1 See Figure 7 43 To check for this condi...

Page 365: ...ge is higher regulator is not functioning prop erly or connections are loose or dirty Stator Check 1 Turn ignition key switch to OFF 2 See Figure 7 45 Connect an ohmmeter a Locate voltage regulator connector 46 behind left footrest support Disconnect from alternator stator wiring b Insert one ohmmeter lead into either stator socket c Attach the other lead to a suitable ground 3 Test for continuity...

Page 366: ...ator sock ets c Run the engine at 2000 RPM The AC output should be 38 52 volts AC 2 Compare test results to specifications a If the output is below specifications charging prob lem could be a faulty rotor or stator b If output is good charging problem might be faulty regulator rectifier Replace as required 3 Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST Figure 7 51 Chec...

Page 367: ...bly is due in part to the magnetic force of the permanent rotor magnets Stator 1 See Figure 7 54 Disconnect stator wiring from voltage regulator wiring at connector 46 located behind left foot rest support 2 Remove cable straps holding stator wire to oil filter hose 3 Withdraw stator wiring from behind the gearcase cover 4 Remove and discard the four TORX screws which secure stator to left crankca...

Page 368: ...e 3 Position stator on left crankcase half Secure stator using four new TORX screws Tighten screws to 30 40 in lbs 3 5 Nm 4 Route stator wiring under starter behind footpeg support bracket and under seat Cable tie connector 46 halves together NOTE Temporarily attach a thin flexible feed or mechanic s wire to the connector end of the stator wiring to assist in the routing of the wiring 5 Connect al...

Page 369: ...eaker c Route charging wire back to voltage regulator 4 Remove two mounting screws 5 Remove and discard voltage regulator INSTALLATION 1 Apply LOCTITE THREADLOCKER 243 Blue to threads of two mounting screws 2 See Figure 7 57 Attach new voltage regulator using two screws Tighten screws to 4 6 ft lbs 5 8 Nm 3 Connect voltage regulator connector 46 to alternator stator wiring Cable tie connector halv...

Page 370: ...2 6V charge the battery and then recheck the voltage after the battery has set for one to two hours If the voltage reading is 12 8V or above perform the load test Figure 7 58 Maintenance Free AGM Battery Figure 7 59 Antidote M A D E I N U S A HARLEY D AVID SON M ILW AUKEE W I 53201 M ADE IN U S A WAR RAN TY AN DAD JU ST MEN TPO LICY Thisbatte ry willbe replace dwithoutch arge iffoun dto be de fect...

Page 371: ... the leads to the battery to avoid dangerous sparks Never try to charge a visibly damaged or frozen bat tery Connect the charger leads to the battery red posi tive lead to the positive terminal and black negative lead to the negative terminal If the battery is still in the vehicle connect the negative lead to the chassis ground Be sure that the ignition and all electrical accessories are turned of...

Page 372: ...led the resulting sparks may cause a battery explosion which could result in death or serious injury CAUTION Overtightening bolts can damage battery terminals 2 See Figure 7 62 Insert bolt through battery positive cable red into threaded hole of battery positive ter minal Tighten bolt to 60 96 in lbs 7 11 Nm 3 See Figure 7 62 Insert bolt through battery negative cable black into threaded hole of b...

Page 373: ...bient temperature and the battery s state of charge Batteries discharge at a faster rate at higher ambient temperatures To reduce the self discharge rate store battery in a cool not freezing dry place See Fig ure 7 63 Charge the battery every month if stored at temperatures below 60 F 16 C Charge the battery more frequently if stored in a warm area above 60 F 16 C NOTE The H D Battery Tender Autom...

Page 374: ...ll front forks through triple clamps and brackets See 2 17 FRONT FORK b See Figure 7 64 Install bracket with two allen screws c Repeat for other bracket d Attach both front turn signals See 7 19 TURN SIG NALS e Install windscreen if removed with four screws and washers See 2 26 WINDSCREEN 2 See Figure 7 64 Attach connector 38 to wiring har ness 3 See Figure 7 64 Install headlamp housing using two ...

Page 375: ...cycle on level floor or pavement in an area with minimum light 3 See Figure 7 65 Point front of motorcycle toward a screen or wall which is 25 ft 7 62 M away from front tire contact patch on floor directly below front axle 4 Draw a horizontal line on the screen or wall 35 in 88 9 cm above the floor 5 Have a person whose weight is roughly the same as that of the principal rider sit on motorcycle se...

Page 376: ...andard phillips screwdriver on the right side headlamp mounting stud to change lateral alignment Turn the stud clockwise to shift beam to the right turn the stud counterclockwise to shift beam to the left c See Figure 7 67 Turn vertical headlamp mounting adjuster clockwise to raise beam height d See Figure 7 67 Turn horizontal headlamp mount ing adjuster clockwise to change lateral alignment Figur...

Page 377: ... 2 Nm 2 See Figure 7 68 Attach the 6 place tail lamp connector to the back of the tail lamp 11WARNING 1WARNING Check for proper tail lamp operation before riding motor cycle Visibility is a major concern for motorcyclists Fail ure to have proper tail lamp operation could result in death or serious injury 3 Check tail lamp for proper operation If operation fails reread procedure and verify that all...

Page 378: ...s on turn signal wires as shown in Figure 7 69 3 Install four screws washers and windscreen See 2 26 WINDSCREEN 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 4 Check turn signals for proper operation If operation fails reread pro...

Page 379: ...e Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 4 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Activate left turn signals using switch on left handle bar Front and rear left turn signals must flash c Act...

Page 380: ...it breaker to clip 4 Connect negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 6 8 10 9 Nm 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 5 Check turn signals for proper operation If operation fails rerea...

Page 381: ...95 behind dash Detach connector 24 from wiring harness 4 Remove connector 95 from clutch switch INSTALLATION Right Side 1 Attach throttle cables to hand control 2 Position housings on right handlebar by engaging stud on front housing with hole in handlebar Fasten housings with two screws Tighten to 25 33 in lbs 2 8 3 7 Nm 3 See Figure 7 74 Route switch housing wiring harness between front forks At...

Page 382: ...operations before riding motorcycle Handlebar switches not operating properly could result in death or serious injury 3 Check handlebar switch for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Check headlamp LOW and HIGH beam settings c Set headlamp to LOW beam Press passing lamp switch Headlamp should flash HIGH ...

Page 383: ...check for the following conditions a Discharged battery b Loose frayed or damaged wiring leading to horn ter minal 2 If battery has a satisfactory charge and wiring appears to be in good condition test horn grounds and switch using voltmeter a See Figure 7 78 Remove Y BK power and BK ground wires from terminal clips b Connect voltmeter positive lead to Y BK wire c Connect voltmeter negative lead t...

Page 384: ...Remove two socket head screws 7 and lockplate 6 CAUTION Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft Transmission sprocket nut will be damaged if turned counterclockwise to remove 4 Remove transmission sprocket nut 5 from main drive gear shaft 3 5 Remove transmission sprocket 4 with secondary drive belt from main drive gear shaf...

Page 385: ...ic breaker contacts automatically close completing the circuit once they have cooled down from the initial over load If the overload condition still exists the breaker contacts will again open to interrupt current flow This opening and closing of the breaker contacts continues as long as the cur rent circuit overload condition exists To replace the circuit breaker 1 Remove seat See 2 28 SEAT 2 Dis...

Page 386: ... ON while holding the reset switch in The normal power up sequence will occur before entering the diagnostic mode Diagnostic codes set during this power up sequence will be stored as well NOTE Make sure no Diagnostic Codes are indicated before reset is held in for more than 5 seconds or diagnostic information will be lost When in the diagnostic mode the odometer will display the first diagnostic c...

Page 387: ...more glass cleaner in gap and work speed ometer free from dash 4 Depress tab and remove speedometer connector 39 INSTALLATION 1 Install connector 39 on back of speedometer 2 Lubricate rubber mount with glass cleaner and insert speedometer into dash panel 3 Install speedometer to dash panel with two screws in back of dash panel 4 Connect connector 20 and replace cable tie to adjacent wire bundle 5 ...

Page 388: ...cially during break in Always clean and troubleshoot speedometer sensor and verify proper operation before replacing speedometer See Speedometer Sensor Test in next section Clean any debris from speedometer sensor INSTALLATION 1 Install speedometer sensor in engine case 2 Install screw and tighten to 80 100 in lbs 9 11 Nm 3 Connect connector 65 in right side frame cavity 4 Install seat See 2 28 SE...

Page 389: ...eter Operation Test 1 See Figure 7 89 Locate the 3 place Deutsch connector 65 for the speedometer sensor to right of battery and disconnect 2 Attach speedometer tester connector to speedometer sensor connector 3 Place speedometer tester power switch in the ON posi tion Place signal switch in the OUT position 4 Turn vehicle ignition switch ON 5 Begin test a Press ENTER on the tester keypad b Enter ...

Page 390: ...8 12 VDC on red wire in connector 65B Then check for continuity to ground on black wire in con nector 65B 1 Raise rear wheel off floor using REAR WHEEL SUP PORT STAND Part No B 41174 2 Install the test harness between the speedometer sensor connectors 65A and 65B 3 Place speedometer tester power switch in the ON posi tion Place signal switch in the IN position 4 Plug the speedometer tester into th...

Page 391: ...oggle switch again and verify operation Does display toggle between trip and odometer modes YES Verify trip display consists of correct numbers Are correct numbers displayed NO Replace speedometer YES Go to Speedometer Test Chart 2A NO Remove boot over trip reset switch Toggle trip reset switch without boot Does display toggle between modes YES Unit OK Return to customer NO Place jump wire across ...

Page 392: ...ve output speed on speedometer while moving shaking vehicle harness connections Outputs erratic YES Replace speedometer Bad connection found Repair con nector or harness YES NO YES Go to Speedometer Test Chart 2B STOP 6008 6004 6006 6008 Go to applicable code in chart d0x YES NO 1 2 1 3 Locate and repair open in O W wire NO Locate and repair open in BK wire 6008 Replace speedometer 6014 YES Repair...

Page 393: ... Check for open wires Wires OK YES Replace speedometer NO Repair wires YES Check speedometer power O W wire and ground terminal BK wire voltage at back of speedometer Test voltage while shaking harness Does voltage fluctuate NO 6 12 VDC is not present Replace speedometer NO 6 12 VDC is present but no fluctuation to 0 1 VDC Replace speedometer sensor YES Repair as necessary NO Check for spark plug ...

Page 394: ... Repair Open in Circuit Replace Speedometer Instrument Connector 20 Terminal Wire Color Indicator 1 Orange White Power 2 Brown Right Turn 3 White High Beam 4 Violet Left Turn 5 Tan Neutral 6 Green Yellow Oil Pressure 7 Black Right Left Turn High Beam 8 Not Used Not Used 9 Red Sensor Power 10 White Sensor Return 11 Black Sensor Ground 12 Not Used Not Used Replace Oil Pressure Switch Repair Open in ...

Page 395: ...that secure main wiring harness to frame Disconnect harness from T studs 8 Disconnect speedometer connector 39 9 Disconnect right and left handlebar switch connectors 22 and 24 front brake switch blade connectors 170 and clutch switch connector 95 10 Tag and disconnect right and left front turn signal bullet connectors 11 Disconnect ignition switch connector 33 12 Note location of cable tie and cu...

Page 396: ...3 to starter relay 3 Connect system relay connector 171 to system relay 4 Install fuse block 5 Connect positive wire to circuit breaker Tighten metal nut to 15 18 in lbs Tighten plastic acorn nut to 1 3 in lbs 0 1 0 3 Nm 6 Feed negative wire across frame and connect to volt age regulator mount and frame Use two cable ties to secure wires 7 See Figure 7 98 Mate speed sensor connector 65 Tuck excess...

Page 397: ... windscreen with four screws and washers See 2 26 WINDSCREEN 30 Install fuel tank 4 2 FUEL TANK COVER FUEL TANK 11WARNING 1WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks could cause a bat tery explosion which could result in serious injury or death 31 Install battery and reconnect battery ca...

Page 398: ...2002 Buell P3 Electrical 7 71 HOME ...

Page 399: ...SUBJECT PAGE NO A 1 TOOLS A 1 B 1 ELECTRICAL CONNECTORS B 1 C 1 METRIC INFORMATION C 1 Table Of Contents APPENDICES ...

Page 400: ...Product 1 2 ...

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