Buell 2002 P3 Service Manual Download

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2002 Buell P3: Maintenance

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Set the torque wrench for the lowest setting in the given
torque range for the fastener.

Attempt to tighten fastener to set torque. If fastener does
not move and lowest setting is satisfied (torque wrench
clicks), then the proper torque has been maintained by
the fastener.

If the fastener does move, remove the fastener, reapply
the appropriate type of LOCTITE THREADLOCKER and
tighten the fastener to Service Manual specification.

REPAIR AND REPLACEMENT

PROCEDURES

Hardware and Threaded Parts

Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding speci-
fied torque.

Replace bolts, nuts, studs, washers, spacers and small com-
mon hardware if missing or in any way damaged. Clean up or
repair minor thread damage with a suitable tap or die.

Replace all damaged or missing lubrication fittings.

Use Teflon pipe sealant on pipe fitting threads.

Wiring, Hoses and Lines

Replace hoses, clamps, electrical wiring, electrical switches
or fuel lines if they do not meet specifications.

Instruments and Gauges

Replace broken or defective instruments and gauges.
Replace dials and glass that are so scratched or discolored
that reading is difficult.

Bearings

Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.

Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant by tapping the bearing against a wooden
block. Wash bearings again. Cover bearings with clean mate-
rial after setting them down to dry. Never use compressed air
to dry bearings.

Coat bearings with clean oil. Wrap bearings in clean paper.

Be sure that the chamfered side of the bearing always faces
the shoulder (when bearings installed against shoulders).
Lubricate bearings and all metal contact surfaces before
pressing into place. Apply pressure only on the part of the
bearing that makes direct contact with 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 bearing/bushing driver or
a bar with a smooth, flat end. Never use a hammer to drive
bushings.

Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.

Gaskets

Always discard gaskets after removal. Replace with

new

gas-

kets. Never use the same gasket twice. Be sure that gasket
holes match up with holes in the mating part.

Lip Type Seals

Lip seals are used to seal oil or grease and are usually
installed with the sealing lip facing the contained lubricant.
Seal orientation, however, may vary under different applica-
tions.

Seals should not be removed unless necessary. Only remove
seals if is necessary to gain access to other parts or if seal
damage or wear dictates replacement.

Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.

Always discard seals after removal and replace with

new

seals. Do not use the same seal twice.

O-Rings (Preformed Packings)

Always discard O-rings after removal. Replace with

new

O-

rings. To prevent leaks, lubricate the O-rings before installa-
tion. Apply the same type of lubricant as that being sealed.
Be sure that all gasket, O-ring and seal mating surfaces are
thoroughly clean before installation.

Gears

Always check gears for damaged or worn teeth.

Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.

Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Dis-
card parts that are worn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mat-
ing parts together tightly.