Page 1 2004 BUELL P3 SERVICE MANUAL Part Number 99492-04Y 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 Edit Me: Printed June 19, 2003 1:24 pm...
Page 3 HOME TOOLS Part No. B-35316-5 12 Inch Bolt. Part No. B-43982 Sprocket Locking Tool Used with Part No. HD-39302. Part No. B-41174 Rear Wheel Support Stand and Part No. B-43983 Main Drive Gear Cross Plate. Part No. B-41174-2 Replacement Pad. Used with Part No.
Page 4 HOME Part No. B-43991 Fork Seal/Bushing Driver Part No. HD-33223-1 Cylinder Compression Gauge Part No. B-59000A Pro Level Oil Gauge Part No. HD-33413-A Carburetor Idle Adjustment Tool Part No. HD-25070 Robinair Heat Gun Part No. HD-33416 Universal Driver Handle Part No. HD-33446A Cylinder Torque Plates Part No.
Page 5 HOME Part No. HD-33813 Inductive Timing Light Part No. HD-34731 Shoulderless Valve Guide Installation Tool Part No. HD-34623B Piston Pin Part No. HD-34736B Valve Spring Compressor Retaining Ring Installer/Remover Part No. HD-34643A Shoulderless Valve Guide Part No. HD-34740 Driver Handle and Remover. Use with Seal Installer Part No.
Page 6 HOME Part No. HD-34902-B Primary Bearing Race Remover/ Part No. HD-35457 Black Light Leak Detector Installer Part No. HD-35102 Wrist Pin Bushing Hone (20 mm) Part No. HD-35500A Digital Multi-Meter (FLUKE 23) Part No. HD-35316-A Main Drive Gear Remover/Installer Part No. HD-35518 Internal/External and Main Drive Gear Bearing Installer.
Page 7 HOME Part No. HD-35758 Neway Valve Seat Cutter Set Part No. HD-38125-8 Packard Terminal Crimp Tool Part No. HD-37842A Inner/Outer Main Drive Gear Part No. HD-38361 Cam Gear Gauge Pin Set Needle Bearing Installer (0.108 in. (2.74 mm) Diameter) Part No. HD-38125-6 Packard Terminal Crimp Tool Part No.
Page 8 HOME Part No. HD-38871- 2 Reamer. Use with Part No. B-43988 Part No. HD-39458 Sprocket Shaft Bearing Outer Camshaft Bushing Reamer Fixture Race Installer Part No. HD-39151 Shift Drum Retaining Ring Installer Part No. HD-39565 Engine Sound Probe Part No. HD-39617 Inductive Amp Probe. Part No.
Page 9 HOME Part No. HD-39782 Cylinder Head Support Part No. HD-39847 Universal Ratcheting Tap/ Reamer Handle Part No. HD-39786 Cylinder Head Holding Fixture Part No. HD-39932 (Steel) or HD-39932-CAR (Carbide) Intake and Exhaust Valve Guide Reamer. Part No. HD-39800 Oil Filter Crusher, Small Part No.
Page 10 HOME Part No. HD-39969 Ultra-Torch UT-100 Part No. HD-41183 Heat Shield Attachment. Use with Part No. HD-25070. Part No. BU-44473 Tool Organizational System Part No. HD-41185 Hose Cutting Tool Part No. HD-41137 Hose Clamp Pliers Part No. HD-41185-1 Oil Hose Cutter-Replacement Blade Part No.
Page 11 HOME Part No. HD-41496 Main Drive Gear Seal Installer Part No. HD-42310-150 Drip Tray. Use with Part No. HD-42310. Part No. HD-41609 Amp Terminal Crimp Tool Part No. HD-42320 Piston Pin Remover/Installer Part No. HD-41675 Oil Pressure Sending Unit Wrench Part No.
Page 12 HOME Part No. HD-42579 Sprocket Bearing/Seal Installer Part No. HD-44358 Flywheel Support Fixture Part No. HD-42774 Sprocket Shaft Seal Installer Part No. HD-43682-10 Drip pan. Use with Part No. HD-43682 or Part No. HD-43646. Part No. HD-43646 Engine Stand Part No. HD-44069 Timkin Snap ring remover and installer.
Page 13 HOME Part No. HD-94547-101 Crankshaft Bearing Outer Race Part No. HD-94803-67 Intake Camshaft Bushing Reamer Remover. Use with Part No. HD-94547-102. Part No. HD-94547-102 Drive Handle. Use with Part No. Part No. HD-94804-57 Rocker Arm Bushing Reamer HD-94547-101. Part No. HD-94660-37B Mainshaft Locknut Wrench Part No.
Page 14 HOME Part No. HD-95017-61 Large External Retaining Part No. HD-95952-33B Connecting Rod Ring Pliers Clamping Tool Part No. HD-95635-46 All-Purpose Claw Puller Part No. HD-95970-32D Piston Pin Bushing Tool Part No. HD-95637-46A Wedge Attachment for Part No. HD-96215-49 Small Internal Retaining Claw Puller.
Page 15 HOME Part No. HD-96333-51C Piston Ring Compressor Part No. HD-96796-47 Valve Spring Tester Part No. HD-96550-36A Valve Lapping Tool Part No. HD-96921-52B Oil Pressure Gauge Part No. HD-96710-40B Crankcase Main Bearing Part No. HD-96921-58 Oil Pressure Gauge Adapter. Lapping Tool Use with Part No.
Page 16 HOME 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 A-14 Appendix A: Tools...
Page 17: Electrical Connectors
HOME ELECTRICAL CONNECTORS GENERAL NOTE Male ends of connectors are labeled “A” in text. Female ends The following table provides a description of the connectors of connectors are labeled “B” in text. found on your motorcycle. Connector numbers are listed in [brackets] in this manual. Table B-1.
Page 18: Deutsch Electrical Connectors
HOME DEUTSCH ELECTRICAL CONNECTORS GENERAL a0266x7x The Deutsch Connector features a seal to protect electrical contacts from dirt and moisture. Three and eight pin connectors are of similar construction with one exception: eight pin connectors use two external latches on the socket side. NOTE Use the DEUTSCH TERMINAL CRIMP TOOL (Part No.
Page 19 HOME CRIMPING INSTRUCTIONS a0267x7x Figure B-3. Squeeze the handles to cycle the DEUTSCH TERMINAL CRIMP TOOL (Part No. HD- Pin housing 39965) to the fully open position. Raise locking bar by pushing up on bottom ﬂange. With the crimp tails facing upward and the rounded side of the contact barrel resting on the concave split level area of Arrow points to the crimp tool, insert contact (socket/pin) through middle...
Page 20: Amp Multilock Electrical Connectors
HOME AMP MULTILOCK ELECTRICAL CONNECTORS SOCKET/PIN TERMINALS a0269x7x Removal If necessary, cut any surrounding cable straps to gain access to the connector. Figure B-4. Depress the button (5) on the socket housing (3). Pull apart the pin and socket halves. Bend back the latch slightly and free one side of second- ary lock, then repeat the step to release the other side.
Page 21 HOME Installation a0271x7x NOTES For wire location purposes, numbers are stamped into the secondary locks of both the socket and pin housings. The tang in the chamber engages the slot to lock the ter- minal in position. On the pin side of the connector, tangs are positioned at the bottom of each chamber, so the slot in the pin termi- nal (on the side opposite the crimp tails) must face down- ward.
Page 22 HOME CRIMPING INSTRUCTIONS a0273x7x Figure B-9. Squeeze the handles to cycle the AMP TERMINAL CRIMP TOOL (Part No. HD-41609) to the Raise locking bar and fully open position. seat contact on nest of crimp tool. Release locking tool. Raise locking bar by pushing up on bottom ﬂange. With the crimp tails facing upward, insert contact (socket/pin) through locking bar, so that the closed side of the contact rests on the nest (concave split level area) of the crimp...
Page 23 BATT ERY STATOR PARK 6A RATING LOCK 12A RATING 6A RATING ZADI KEY SW I TCH 16 R/B K 18 O/ W KEY SW I TCH LOGI C Figure B-10. 2004 Buell Blast P3 Model - Main Harness Appendix B: Wiring...
Page 24 START RELAY D C B A CLUTCH SWITCH TN/GN TN/GN BK/R TN/GN R/BK R/B 1 START RELAY KEY SWITCH R/BK FUSE BLOCK R/BK1 (TOP VIEW) SYSTEM RELAY BATTERY Figure B-11. 2004 Buell Blast P3 Model - Starting Appendix B: Wiring...
Page 25 CONNECTOR CODE: LIGHT BLACK BLUE DIODE BROWN GREEN PIN CONNECTOR GRAY ORANGE SOCKET CONNECTOR PINK SPLICE CONNECTION VIOLET NO CONNECTION WHITE YELLOW BK 2 BK 3 BK 3 Figure B-12. 2004 Buell Blast P3 Model - Charging Appendix B: Wiring...
Page 26 HIGH BEAM HORN Y/BK LEFT TURN RIGHT TURN HORN POWER D C B A TN/Y HORN Y/BK R/GY KEY SWITCH R/BK R/B 1 SYSTEM RELAY Figure B-13. 2004 Buell Blast P3 Model - Horn and Instruments B-10 Appendix B: Wiring...
Page 27 LIGHT POWER HIGH BEAM FROM FLASHER V/BN LEFT TURN RIGHT TURN D C B A FLASHER R/GY KEY SWITCH R/BK FUSE BLOCK R/BK1 (TOP VIEW) SYSTEM RELAY BATTERY Figure B-14. 2004 Buell Blast P3 Model - Lighting Appendix B: Wiring B-11...
Page 28 CLUTCH SW I TCH TN/ GN R/ BK KEY SW I TCH R/ BK FUSE BLO CK R/ BK1 ( TOP VI EW ) SYSTEM RELAY BATTERY Figure B-15. 2004 Buell Blast P3 Model - Ignition B-12 Appendix B: Wiring...
Page 29 HOME METRIC CONVERSIONS MILLIMETERS TO INCHES INCHES TO MILLIMETERS (MM X 0.03937 = INCHES) (INCHES X 25.40 = MM) in. mm in. mm in. mm in. in. mm in. mm in. mm in. .0039 .9842 2.283 3.582 .001 .025 15.240 49.21 84.14 .0078...
Page 30 HOME UNITED STATES SYSTEM BRITISH IMPERIAL SYSTEM Fluid volume measurements in this Service Manual do not Unless otherwise speciﬁed, all ﬂuid volume measurements include the British Imperial (Imp.) system equivalents. The fol- in this Service Manual are expressed in United States (U.S.) units-of-measure.
Page 31: Table Of Contents
MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fluid Requirements .
Page 32: Maintenance
Engine oil and transmission ﬂuid levels. Always clean around lines or covers before they are removed. Headlamp, passing lamp, tail lamp, brake lamp and turn Plug, tape or cap holes and openings to keep out dirt, dust signal operation. and debris. 2004 Buell P3: Maintenance...
Page 33: Repair And Replacement Procedures
Always use the proper tools and ﬁxtures for removing and installing bearings. Part Replacement Bearings do not usually need to be removed. Only remove bearings if necessary. Always replace worn or damaged parts with new parts. 2004 Buell P3: Maintenance...
Page 34: Part Protection
When breaking loose a fastener, apply a small amount of Always cut at right angles. pressure as a test to be sure the ratchet’s gear wheel is Don’t use any prybar as a chisel, punch or hammer. engaged with the pawl. 2004 Buell P3: Maintenance...
Page 35: Storage Units
Close lids and lock drawers and doors before moving storage units. Don’t pull on a tool cabinet; push it in front of you. Set the brakes on the locking casters after the cabinet has been rolled to your work. 2004 Buell P3: Maintenance...
Page 36: Fluid Requirements
Should you need to convert from descending order, are 20W-50, 15W-40 and 10W-40. At the U.S. units to British Imperial units (or vice versa), refer to the ﬁrst opportunity, see a Buell dealer to change back to 100 following: percent Harley-Davidson oil.
Page 37: Maintenance Schedule
The following codes are for the REGULAR MAINTENANCE INTERVALS Table: I - Inspect & if necessary correct, clean or replace. A - Adjust. R - Replace or change. T - Tighten to proper torque L - Lubricated with speciﬁed lubricant X - Perform 2004 Buell P3: Maintenance...
Page 38: Body Panel Care/Maintenance
Products recommended for the proper care and maintenance Polishing of molded-in-color body panels are available at your Buell dealer and are listed below: Polishing molded-in-color body panels results in greater sur- face gloss and a protective coating.
Page 39 HOME NOTES 2004 Buell P3: Maintenance...
Page 40: Battery
Install seat. See 2.28 SEAT. CAUTION Overtightening bolts can damage battery terminals. 2004 Buell P3: Maintenance...
Page 41: Engine Lubrication System
SAE 20W50 HD 360 Above 40˚ F (4˚ C) Good HD Regular Heavy SAE 50 HD 360 Above 60˚ F (16˚ C) Poor HD Extra Heavy SAE 60 HD 360 Above 80˚ F (27˚ C) Poor 1-10 2004 Buell P3: Maintenance...
Page 42: Checking Engine Oil Level
Hot oil level should be between the upper and lower “ﬁll” marks on dipstick. If oil level is down to or below lower “ﬁll” mark on dipstick, add only enough oil to bring level between lower and upper “ﬁll” marks. 2004 Buell P3: Maintenance 1-11...
Page 43 Drain oil after operating motorcycle (while oil is still very warm). Replace oil ﬁlter every time the oil is changed. Drain the crankcase breather drain hose of any accumu- lated oil every time the oil is changed. 1-12 2004 Buell P3: Maintenance...
Page 44: Brake System Maintenance
In case of contact with skin or eyes, ﬂush with plenty of water. Get medical attention for eyes. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN. Failure to comply could result in death or serious injury. 2004 Buell P3: Maintenance 1-13...
Page 45: Loosen Locknut
Tighten locknut. full range of travel, close bleeder valve (clockwise). Allow brake lever/pedal to return slowly to its released position. NOTE Repeat Steps 2-4 until all air bubbles are purged. Brake pedal has no freeplay adjustment. 1-14 2004 Buell P3: Maintenance...
Page 46: Brakes Pads And Rotors
The brake rotor must be within the following speciﬁca- tions. If the brake rotor is suspected of being damaged, inspect rotor using the following measurements: Lateral Movement: 0.01-0.02 in. (0.3-0.5 mm). Radial Movement: 0.02 in. (5.1 mm). Rotational Movement: 0.02 in. (5.1 mm). 2004 Buell P3: Maintenance 1-15...
Page 47: Tires And Wheels
Check wheel bearings for wear and corrosion. Excessive play or roughness indicates worn bearings. Replace bearings in A bump, bulge or split in the tire. sets only. Puncture, cut or other damage to the tire that cannot be repaired. 1-16 2004 Buell P3: Maintenance...
Page 48: Clutch
Figure 1-12. Slide rubber boot (1) upward to expose adjuster mechanism. Loosen jam nut (3) from adjuster (4). Turn adjuster to shorten cable housing until there is a large amount of freeplay at clutch hand lever. 2004 Buell P3: Maintenance 1-17...
Page 49 Bracket pattern to 84-108 in-lbs (9.5-12.2 Nm). 11. Check clutch cable freeplay. See Step 6 above. Figure 1-14. Adjusting Clutch Freeplay 12. Install left footpeg support bracket. See 2.21 FOOT- PEGS AND FOOTPEG SUPPORT BRACKETS. 1-18 2004 Buell P3: Maintenance...
Page 50: Transmission/Primary Fluid
Install seat. See 2.28 SEAT. Magnetic drain plug (with o-ring) Figure 1-15. Primary Cover Figure 1-15. Remove three TORX screws with washers (1) from clutch inspection cover (2). Remove clutch inspection cover from primary cover. 2004 Buell P3: Maintenance 1-19...
Page 51: Changing Transmission Fluid
Remove three TORX screws with washers (1) from cle and death or serious injury. clutch inspection cover (2). Remove clutch inspection cover from primary cover. 12. Install seat. See 2.28 SEAT. 1-20 2004 Buell P3: Maintenance...
Page 52: Drive Belt And Rear Sprocket
Condition 1 is not grounds for replacing the belt, but it should Replace belt and drive sprocket that exceed maximum be watched as it may develop into condition 2 or 3 resulting in allowable deﬂection. a need for belt replacement. 2004 Buell P3: Maintenance 1-21...
Page 53 OK to run, but monitor condition Fuzzy edge cord OK to run, but monitor condition Hook wear Replace belt Stone damage Replace belt if damage is on the edge Bevel wear (outboard edge only) OK to run, but monitor condition 1-22 2004 Buell P3: Maintenance...
Page 54 Pull axle out. Remove right side spacer. Slide carrier with caliper off rotor. Remove left side spacer. Move wheel forward and slide belt off. 10. Remove sprocket cover and ﬁve washers from sprocket. 11. Remove and discard sprocket. Discard ﬁve washers. 2004 Buell P3: Maintenance 1-23...
Page 55 If seat is loose, it could shift Figure 1-21. Rear Axle, Right Side during vehicle operation and startle the rider, causing loss of control and personal injury. 28. Install seat. See 2.28 SEAT. 1-24 2004 Buell P3: Maintenance...
Page 56: Primary Chain
At every 2500 mile (4000 km) interval thereafter. ADJUSTMENT Figure 1-22. Buell Blast Models are shipped with a spacer between the primary chain limiting screw and the lock- nut. The spacer is used to quickly get proper adjustment dur- ing production. This spacer should be removed and discarded at the ﬁrst adjustment interval.
Page 57: Rear Shock Absorber
Damper component (3) cannot be serviced or repaired. If the damper component is leaking or damaged it must be replaced. Bolt Damper bushing Damper component Stopper ring Spring seat Spring Spring seat stopper Figure 1-25. Rear Shock Absorber Assembly 1-26 2004 Buell P3: Maintenance...
Page 58: Front Fork Oil
Spring collar Lower spring joint Spring Figure 1-29. Removing Sub-Assembly Figure 1-27. Slider Tube Cap Figure 1-29. Remove the spring collar, lower spring joint and spring from slider tube. Figure 1-27. Remove slider tube cap. 2004 Buell P3: Maintenance 1-27...
Page 59 10. Install new O-ring onto spring seat. 3769 Figure 1-31. Compressing Spring Seat 11. See Figure 1-31. Push down on spring seat past groove to install stopper ring. Stopper ring will lock into groove when installed correctly. 1-28 2004 Buell P3: Maintenance...
Page 60: Steering Head Bearings
Install seat and fuel tank. See 4.2 FUEL TANK COVER/ FUEL TANK. NOTE Check that clutch and throttle cables do not bind when mea- suring bearing resistance. 2004 Buell P3: Maintenance 1-29...
Page 61 (32,000 km) thereafter, lubricate the steering head bearings Pinch screws (2) with WHEEL BEARING GREASE (Part No. 99855-89). Dust shield (2) Bearing (2) Bearing cup (2) Lower triple clamp Pinch screws (2) Figure 1-34. Fork Stem and Bracket Assembly 1-30 2004 Buell P3: Maintenance...
Page 62: Spark Plug
The condition may be caused by one or more of the following: worn pistons, worn piston rings, worn valves, worn valve guides, worn valve seals, a weak battery or a faulty ignition system. 2004 Buell P3: Maintenance 1-31...
Page 63: Air Cleaner
(gold) at top of venturi ring. Remove screw with spacer. Remove remaining two allen head screws to free venturi ring from carburetor ﬂange. Remove hex screw at bottom of air box (6 o’clock posi- tion) to release bracket from crankcase hole. 1-32 2004 Buell P3: Maintenance...
Page 64: Cleaning And Inspection
Slide spacer onto longer allen head screw (gold), if removed. Apply a small dab of Loctite 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 (2.0.-2.5 Nm). 2004 Buell P3: Maintenance 1-33...
Page 65: Throttle Cables
Recheck engine slow idle speed; adjust if required. travel. If engine speed changes during this maneuver, adjust throttle cables as follows: 6853a Cable adjuster lock Idle control cable Cable adjuster Rubber boot Throttle control cable Figure 1-40. Throttle Cables 1-34 2004 Buell P3: Maintenance...
Page 66: Ignition Timing And Idle Speed Adjustment
With timing light aimed into inspection hole, rotate mod- ule plate until advance timing mark is centered in timing inspection hole as shown in Figure 1-41. 2004 Buell P3: Maintenance 1-35...
Page 67: Idle Speed Adjustment
1200 RPM. Turn the ignition switch to off position. Ignition coil cable Fuel supply valve Tachometer button Figure 1-44. Checking RPM Using a Hand Held Tachometer 1-36 2004 Buell P3: Maintenance...
Page 68: Fuel Supply Valve And Filter Strainer
“RES(ERVE)” (6) of to start the ﬂow of fuel. Fuel supply - “RESERVE” position Once the fuel tank is completely drained, rotate han- Figure 1-45. Fuel Supply Valve dle of fuel supply valve to “OFF”. Remove spare hose from outlet ﬁtting. 2004 Buell P3: Maintenance 1-37...
Page 69 Position seat on frame backbone, 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. 1-38 2004 Buell P3: Maintenance...
Page 70: Starter Interlock And Electrical Switches 1.22
Clutch disengaged (lever pulled in - must be done when- ever 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. 2004 Buell P3: Maintenance 1-39...
Page 71: Headlamp
Check light beam for proper lateral alignment. Main beam of light should be directed straight ahead (i.e. equal area of light to right and left of center). Adjust headlamp if necessary. See ADJUSTMENT. 1-40 2004 Buell P3: Maintenance...
Page 72: Critical Fastener Torque Values
30-39 Nm Mufﬂer fasteners (front and rear) 22-25 ft-lbs 30-34 Nm Tie bar (all) 30-33 ft-lbs 41-45 Nm Front isolator mounting bolt 63-70 ft-lbs 86-95 Nm Frame to rear isolator fastener 30-33 ft-lbs 41-45 Nm 2004 Buell P3: Maintenance 1-41...
Page 73: Storage
This work should be performed by your local Buell dealer or If motorcycle is to be covered, use a material that will other qualiﬁed technician following Service Manual proce- breathe, such as light canvas.
Page 74: Troubleshooting
Insufﬁcient oil supply, or oil not circulating. closed off restricting fuel ﬂow. Leaking valves. 10. Water or dirt in fuel system and carburetor. Heavy carbon deposit. 11. Enrichener valve inoperative. 12. Air leak at intake manifold. Ignition timing retarded. 2004 Buell P3: Maintenance 1-43...
Page 75: Electrical System
Rectiﬁer not grounded. Clutch plates excessively warped. Engine ground wire loose or broken. Loose or broken wires in charging circuit. Chatters Stator not functioning. Rotor not functioning. Friction or steel plates worn, warped, or dragging. 1-44 2004 Buell P3: Maintenance...
Page 76 2.18 FORK STEM AND BRACKET ASSEM- BLY. 10. Shock absorber not functioning normally. 11. Heavy front end loading. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment, or luggage) tends to cause unstable han- dling. 2004 Buell P3: Maintenance 1-45...
Page 77 HOME NOTES 1-46 2004 Buell P3: Maintenance...
Page 78 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 80: Specifications
See information decal on frame steering head for Gross Vehi- cle Weight Rating (GVWR) (maximum allowable loaded vehi- Dunlop Tires FRONT REAR (only) cle weight) and corresponding Gross Axle Weight Ratings (GAWR). Solo rider Rider & passenger 2004 Buell P3: Chassis...
Page 81: Torque Values
Rear brake caliper mounting screw, 15-18 ft-lbs 20-24 Nm Metric, Page 2-39 small Rear brake caliper pad hanger pin 11-15 ft-lbs 15-20 Nm Metric, Page 2-38 Rear brake fastener 72-96 in-lbs 8-11 Nm Page 2-60 2004 Buell P3: Chassis...
Page 82 17-19 ft-lbs 23-26 Nm threads, Page 2-56 Switchgear housing screws, right side 12-17 in-lbs 1-2 Nm Metric, Page 2-42 Valve stem nut 42-44 in-lbs 4.7-5.0 Nm Page 2-20 Windscreen screws 9-11 in-lbs 1-1.2 Nm Page 2-66 2004 Buell P3: Chassis...
Page 83: Tire Specifications
RIM SIZE HOLE DIAMETER 16 in. – Front MT 2.5 x 16.0 DOT 0.33 in. (8.38 mm) 100/80 16 K330 16 in. – Rear MT 2.75 x 16.0 DOT 0.33 in. (8.38 mm) 120/80 16 K330 2004 Buell P3: Chassis...
Page 84: Vehicle Identification Number
Always give the full 17-digit Vehicle Identiﬁcation Number Figure 2-1. Each vehicle has a 17-digit serial or Vehicle when ordering parts or making inquiries about your Buell Identification Number (V.I.N.) stamped on the steering head. motorcycle. A Motor Identification Number is stamped on the left side crankcase near the front of the engine.
Page 85: Wheels
Correct adjustment and replace pitted or worn bearings. See 2.18 FORK STEM AND BRACKET ASSEMBLY. Damper tubes. Check for leaks. See 2.17 FRONT FORK. Shock absorber. Check damping action and mounts. See 2.15 REAR SHOCK ABSORBER. Swingarm bearings. Check for looseness. See 2.19 SWINGARM. 2004 Buell P3: Chassis...
Page 86 In some 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).
Page 87: Front Wheel
Figure 2-5. Insert screwdriver/rod through axle hole (1). Loosen front axle nut (4). Loosen pinch screw (2). Remove front axle nut, spacer and washer. Pull front axle out of wheel hub while supporting front wheel. 2004 Buell P3: Chassis...
Page 88 Left axle spacer Wheel bearing Wheel Valve stem Wheel weight Axle spacer, center Wheel bearing Front axle 10. Brake rotor bolt (5) 11. Brake rotor washer (5) 12. Front brake rotor 13. Washer Figure 2-6. Front Wheel Assembly 2004 Buell P3: Chassis...
Page 89 Install tire, if removed. See TIRES. 22 Nm). Verify that wheel and tire are true. See 2.8 CHECKING Install front brake caliper. See 2.11 FRONT BRAKE CAST RIM RUNOUT. CALIPER. Balance tire. See 2.9 TIRES, ADJUSTMENT. 2-10 2004 Buell P3: Chassis...
Page 90: Rear Wheel
Inspect brake rotor. Move wheel forward and slide belt off. Measure rotor thickness. Replace if less than 4.5 mm. See 2.14 REAR BRAKE CALIPER. Check rotor surface. Replace if warped or badly scored. Inspect tire. See TIRES. 2004 Buell P3: Chassis 2-11...
Page 91 Wheel bearing (left side) Wheel Axle spacer, center Wheel bearing Rear axle Brake rotor screw (5) Rear brake rotor 10. Right axle spacer 11. Lockwasher 12. Right axle spacer a0079x2x Figure 2-9. Rear Wheel Assembly 2-12 2004 Buell P3: Chassis...
Page 92 Hold left side spacer in place and slide rear axle nut to 48-52 ft-lbs (65-71 Nm). caliper and carrier over rotor. Slide belt on sprocket teeth by rotating wheel to “walk” belt onto teeth. Lower motorcycle rear wheel. 2004 Buell P3: Chassis 2-13...
Page 93: Sealed Wheel Bearings
Insert assembly through hole in bridge (5). Drop ball bearing inside collet (6). Fasten collet and ball bearing to forcing screw (1). Hold end of forcing screw (1) and turn collet (6) to expand edges of collet. 2-14 2004 Buell P3: Chassis...
Page 94 Sparingly apply graphite lubricant to threads of threaded rod to prolong service life and ensure smooth operation. Figure 2-15. Place threaded rod through sup- port plate. Insert assembly through wheel. a0202x2x Figure 2-15. Installation Tool Support Plate 2004 Buell P3: Chassis 2-15...
Page 95 10. Pilot 3/4 in. (Part No. B-43993-6) 11. Pilot 1.0 in. (Part No. B-43993-8) 12. Support plate pilot (Part No. B-43993-1) 13. Threaded rod pilot (Part No. 280856) Figure 2-17. Wheel Bearing Remover/Installer (Part No. B-43933) 2-16 2004 Buell P3: Chassis...
Page 96: Checking Cast Rim Runout
Table 2-7. Cast Wheel Runout MEASUREMENT a0206x2x MAXIMUM LATERAL RUNOUT 0.040 1.02 MAXIMUM RADIAL RUNOUT 0.030 0.76 Gauge Rod Figure 2-19. Checking Cast Rim Radial Runout using Wheel Truing and Balancing Stand (Part No. HD-99500-80) 2004 Buell P3: Chassis 2-17...
Page 97: Tires
Failure to heed this warning could result in rear wheel. Improper mounting can result in premature death or serious injury. tire failure and handling problems, which may cause an accident which could result in death or serious injury. 2-18 2004 Buell P3: Chassis...
Page 98 Clean inside of tire. bead drops into rim well. If rim is dirty or corroded, clean with a stiff wire brush. Inspect tire for wear and damage. Replace worn tires. See. 2004 Buell P3: Chassis 2-19...
Page 99 WARNING Excessive force may damage tire or rim and adversely affect handling which could result in death or serious Dunlop front and rear tires for Buell motorcycles are not injury. the same. They are not interchangeable. Use front tire ONLY for a front tire. DO NOT put a rear tire on the front Position red dot at valve stem and starting 180 degrees of a vehicle.
Page 100: Wheel Balancing
Press weight ﬁrmly in place and hold for ten seconds. RUNOUT. Replace rims not meeting speciﬁcations. Allow eight hours for adhesive to cure completely before Install tire and check tire tread radial runout again. using wheel. 2004 Buell P3: Chassis 2-21...
Page 101: Front Brake Master Cylinder
Unplug both terminals to detach brake lamp switch. NOTE The individual parts of the brake lamp switch are not service- able. Replace switch upon failure. Remove two screws (1) (metric) and clamp (2) to detach master cylinder assembly from handlebar. 2-22 2004 Buell P3: Chassis...
Page 102 Remove piston assembly (1-4) from Tang front master cylinder. Front brake switch Figure 2-29. Front Brake Switch Figure 2-29. Remove screw, lockwasher and washer (1) holding front brake switch (3) to master cylinder assembly. Remove switch. 2004 Buell P3: Chassis 2-23...
Page 103 Inspect piston bore in master cylinder housing for scor- Inspect boot for cuts, tears or general deterioration. ing, pitting or corrosion. Replace housing if any of these conditions are found. Replace as necessary. 2-24 2004 Buell P3: Chassis...
Page 104 Align hole in lever with hole in master cylinder assembly. Lubricate pivot bolt (2) with LOCTITE ANTI-SEIZE. Install pivot bolt through top of assembly. Tighten to 4-13 in-lbs (0.5-1.5 Nm). Install nut (1) (metric). Tighten to 44-62 in-lbs (5- 7 Nm). 2004 Buell P3: Chassis 2-25...
Page 105: Verify Proper Operation Of The Master Cylinder Relief Port
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. 2-26 2004 Buell P3: Chassis...
Page 106: Front Brake Caliper
Separate carrier and caliper. Pin plug Mounting screws (2) Wireform Figure 2-37. Front Brake Caliper Figure 2-37. Remove banjo bolt (3) (metric) and two banjo washers (4) to disconnect brake line (1) from cali- per. Discard banjo washers. 2004 Buell P3: Chassis 2-27...
Page 107 Install two new seals (3) in inner grooves of each piston bore. Install pistons (2) in each piston bore. Install a new bleeder valve (metric) if necessary. Tighten to 36-60 in-lbs (4-7 Nm). 2-28 2004 Buell P3: Chassis...
Page 108 Figure 2-41. Connect brake line (1) to caliper using two new banjo washers (4) and banjo bolt (3) (metric). Tighten to 16-20 ft-lbs (22-27 Nm). Route brake line through wireform. 2004 Buell P3: Chassis 2-29...
Page 109 ﬂuid level is 0.125 in. (3.2 mm) from molded boss Avoid making hard stops for the ﬁrst 100 miles (160 km) to inside reservoir. Add D.O.T. 4 BRAKE FLUID if neces- allow new brake pads to “wear in” properly with the brake sary. rotor. 2-30 2004 Buell P3: Chassis...
Page 110: Front Brake Line
Turn ignition key switch to IGN. Apply brake hand lever to clamp (5) from right side of lower triple clamp. Remove test brake lamp operation. Turn ignition key switch to brake line from wireform. LOCK. 2004 Buell P3: Chassis 2-31...
Page 111: Rear Brake Master Cylinder
Turn rod assembly (9) to free rod from clevis (13). Screw (2) (metric Spacer (2) Piston assembly Rod assembly 10. Snap ring 11. Rubber boot 12. Locknut 13. Clevis 14. Clevis pin Figure 2-46. Rear Master Cylinder Assembly 2-32 2004 Buell P3: Chassis...
Page 112 Figure 2-47. Master Cylinder Mounting Remove piston assembly (4) from master cylinder body. Figure 2-47. Remove two screws (2) and spacers (3) to detach master cylinder from footrest support. 7703 Figure 2-48. Remote Reservoir Figure 2-48. Detach remote reservoir. 2004 Buell P3: Chassis 2-33...
Page 113 Place round side of rod assembly (3) over piston. Depress piston into master cylinder body (1) and secure with a new snap ring (2). Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2-34 2004 Buell P3: Chassis...
Page 114 WARNING WARNING To avoid leakage after assembly, verify that banjo wash- ers, banjo bolt, hydraulic brake line and bore of master cylinder are completely clean. 2004 Buell P3: Chassis 2-35...
Page 115 Banjo bolt (metric) Banjo washers (2) Master cylinder Screw (2) (metric Spacer (2) Piston assembly Push rod 10. Snap ring 11. Rubber boot 12. Locknut 13. Clevis 14. Clevis pin Figure 2-53. Rear Master Cylinder Assembly 2-36 2004 Buell P3: Chassis...
Page 116: Rear Brake Caliper
Figure 2-56. Removing Rear Brake Caliper Piston Figure 2-56. Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore. Discard o-rings. 2004 Buell P3: Chassis 2-37...
Page 117 (2). Install pad hanger pin (metric). Tighten to 132-180 in-lbs (15-20 Nm). Install pin plug. Tighten to 18-25 in-lbs (2-3 Nm). Install a new bleeder valve (metric) if necessary. Tighten to 36-60 in-lbs (4-7 Nm). 2-38 2004 Buell P3: Chassis...
Page 118 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell strongly recommends that all brake repairs be performed by a Buell dealer or other qualiﬁed techni- cian. NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in”...
Page 119: Master Cylinder
Distorted, glazed or contaminated brake pads. Replace pads. Brake pads drag on rotor – Cup in master cylinder not uncovering relief Inspect master cylinder. will not retract. port. Rear brake pedal linkage out of adjustment. Adjust linkage. 2-40 2004 Buell P3: Chassis...
Page 120: Rear Shock Absorber
Remove lifting straps and install seat. See 2.28 SEAT. Bolt Damper bushing Damper component Stopper ring Spring seat Spring Spring seat stopper Figure 2-60. Rear Shock Absorber Assembly 2004 Buell P3: Chassis 2-41...
Page 121: Throttle Control
Attach housings with two screws, installing longer screw on bottom. Tighten to 12-17 in- lbs (1-2 Nm). Adjust cables. See 1.19 THROTTLE CABLES. 10. Install fuel tank. See 4.2 FUEL TANK COVER/FUEL TANK. 2-42 2004 Buell P3: Chassis...
Page 122: Front Fork
16. Guide bushing 17. Slider tube 18. Fork assembly (slider & tube, right & left) 19. Slider assembly (left & right) 20. Front fork bolt 21. Center bolt 22. Reﬂector Figure 2-63. Front Fork Assembly 2004 Buell P3: Chassis 2-43...
Page 123 Figure 2-64. Headlamp Bracket Screws Figure 2-64. Loosen headlamp bracket screws. 3765 Figure 2-65. Upper and Lower Triple Clamp Pinch Screws Figure 2-65. Loosen the large pinch screws on both the upper and lower triple clamps. 2-44 2004 Buell P3: Chassis...
Page 124 Spring collar Lower spring joint Figure 2-68. Slider Tube Cap Spring Figure 2-70. Removing Sub-Assembly Figure 2-68. Remove slider tube cap. Figure 2-70. Remove the spring collar, lower spring joint and spring from slider tube. 2004 Buell P3: Chassis 2-45...
Page 125 Figure 2-73. Remove the damper assembly, lock piece and the rebound spring from the slider tube. 3771 Figure 2-72. Removing Center Bolt Figure 2-72. Remove the center bolt (metric) from the bottom of the fork tube. 2-46 2004 Buell P3: Chassis...
Page 126 3773 Oil seal Back-up ring Guide bushing Figure 2-75. Removing Slider Tube 10. See Figure 2-75. Pull the slider tube out of the slider assembly. Remove oil seal, back-up ring and guide bush- ing. 2004 Buell P3: Chassis 2-47...
Page 127 0.008 in. (0.2 mm). Retaining ring Guide bushing Slider tube Slide bushing Figure 2-77. Slider tube Components Figure 2-77. Check the slider tube for score marks, scratches and excessive or abnormal wear. Replace if worn or damaged. 2-48 2004 Buell P3: Chassis...
Page 128 Figure 2-82. Clamping the Slider Assembly Figure 2-82. Clamp the slider assembly in a vise with front fork holding tool (Part No. B-41177). Figure 2-80. Damper Assembly Figure 2-80. Install damper assembly and rebound spring into slider tube. 2004 Buell P3: Chassis 2-49...
Page 129 3796 Figure 2-86. Install Guide Bushing 10. See Figure 2-86. Install guide bushing onto the slider tube. Figure 2-84. Install Rebound Spring Figure 2-84. Install spring onto damper assembly. 2-50 2004 Buell P3: Chassis...
Page 130 15. See Figure 2-90. Install retaining ring. Verify ring is installed securely in the groove inside slider assembly. Figure 2-88. Oil Seal and Backup Ring 13. See Figure 2-88. Install oil seal spacer and backup ring. 2004 Buell P3: Chassis 2-51...
Page 131 18. Pour 9.2 oz. (272 ml) fork oil into fork. 19. Install lower spring joint and spring collar. 20. Coat a new o-ring with fork oil or sealing grease. 21. Install new o-ring onto spring seat. 2-52 2004 Buell P3: Chassis...
Page 132 Triple Clamp Pinch Screws Install front wheel. See 2.5 FRONT WHEEL. Install front brake caliper. See 2.11 FRONT BRAKE Figure 2-96. Apply LOCTITE ANTI-SEIZE to the CALIPER. threads of triple clamp pinch screws. Align headlamp. See 1.23 HEADLAMP. 2004 Buell P3: Chassis 2-53...
Page 133: Fork Stem And Bracket Assembly
Replace if necessary. Capnut Center cap pinch screw Upper triple clamp Pinch screws (2) Dust shield (2) Bearing (2) Bearing cup (2) Lower triple clamp Pinch screws (2) Figure 2-99. Fork Stem and Bracket Assembly 2-54 2004 Buell P3: Chassis...
Page 134 Insert lower triple clamp (8) through the steering head. Install the upper bearing (6) with small end down and 12. Install seat. See 2.28 SEAT. dust shield (5) onto fork stem. 2004 Buell P3: Chassis 2-55...
Page 135: Swingarm
Install rear fender, lower belt guard, and sprocket cover. Loosely install right side footpegs mount. 10. Install reservoir, master cylinder, and brake pedal. Tighten brake pedal bolt to 72-96 in-lbs (8-11 Nm). 11. Tighten footpeg mounting bracket. 2-56 2004 Buell P3: Chassis...
Page 136: Exhaust System
Install retaining ring oriented 90° from exhaust studs (2). scratching the frame and/or painted parts. Failure to do so may result in corrosion of parts. NOTE Retaining ring may crack if not oriented as stated in step 3. 2004 Buell P3: Chassis 2-57...
Page 137: Screw
Clamp, exhaust ring 12. Nut (2) Bolt 13. Nut (2) Screw 14. Mufﬂer, complete Screw 15. Mufﬂer strap, rear Washer (6) 16. Bracket (2) Spacer 17. Grommet (2) Spacer, right Figure 2-101. Exhaust System Assembly 2-58 2004 Buell P3: Chassis...
Page 138: Footpeg Support Brackets
Align footpeg mounting holes with Clamp footpeg support bracket mounting holes. Oil tank drain hose Insert dowel pin (and on rear peg, spacer) through Breather hose mounting holes. Figure 2-103. Left Side Footpeg Support Bracket Install new cotter pin. 2004 Buell P3: Chassis 2-59...
Page 139: Sprocket Cover
Tighten pedal bolt to 72-96 in-lbs (8-11 Nm). Install master cylinder bolts and spacers. See 2.13 REAR BRAKE MASTER CYLINDER. Bolts Spacers Pedal bolt Figure 2-104. Master Cylinder Mounting a0131x2x Screws (3) Nylon washers (3) Figure 2-105. Sprocket Cover Fasteners 2-60 2004 Buell P3: Chassis...
Page 140: Fenders
Tighten fender mounting screws to 27-30 in-lbs (3.1- 3.4 Nm). Mounting screw (4) Washers (4) Figure 2-106. Front Fender Assembly Mounting Screws Figure 2-106. Remove four lower fender mounting screws. 3804 Figure 2-107. Removing Front Fender Figure 2-107. Remove front fender. 2004 Buell P3: Chassis 2-61...
Page 141: Rear Fender Removal
Screws, rear fender mounting (4) Washers (4) Well nuts (4) Clamp, rear brake line Fender, rear Figure 2-108. Rear Fender Assembly Figure 2-108. Remove rear fender mounting screws and washers from rear fender. Remove rear fender. 2-62 2004 Buell P3: Chassis...
Page 142: Lower Belt Guard
Position belt guard over tabs on swingarm. Secure belt guard with two screws and nylon washers. Tighten screws to 30-36 in-lbs (3-4 Nm). Lower belt guard Screws (2) Nylon washers (2) Figure 2-109. Lower Belt Guard 2004 Buell P3: Chassis 2-63...
Page 143: Tail Section And Rear Frame Assembly
10. Rear frame 11. Bolt 12. Rear subframe mounting bracket 13. Screw 14. Bushing 15. Seat latch lever 16. Washer 17. Seat latch spring 18. Bolt 19. Bolt 20. Clamp a0146a2x Figure 2-110. Tail Section 2-64 2004 Buell P3: Chassis...
Page 144 Slide rear frame assembly (10) into cle and death or serious injury. frame. Install seat. See 2.28 SEAT. Install fasteners (11). Install brackets (12) and fasteners (13). Connect rear wire harness and mount on “T” stud. 2004 Buell P3: Chassis 2-65...
Page 145: Windscreen
Tighten screws to 9-11 in-lbs (1-1.2 Nm). Figure 2-111. Remove Screws Remove windscreen. 3797 Figure 2-112. Windscreen Trim Figure 2-112. Remove windscreen trim. Remove windscreen mounting brackets, if required. See 7.17 HEADLAMP. 2-66 2004 Buell P3: Chassis...
Page 146: Instrument Panel
Apply LOCTITE 243 (Blue) to threads of mounting screws. Install dash with two mounting screws. Tighten screws to 30-36 in-lbs (3-4 Nm). Screws (2) Odometer reset switch rubber boot Odometer reset switch Sensor, speed Connector [39] Figure 2-113. Instrument Panel 2004 Buell P3: Chassis 2-67...
Page 147: Seat
If seat is loose, it could shift during operation of vehicle and result in death or serious injury. Figure 2-115. Underside View of Seat with Locating Tab Verify seat is locked in position. 2-68 2004 Buell P3: Chassis...
Page 148: Sidestand
Test the sidestand in the following manner. Without vehicle weight resting on it, sidestand should move freely into extended (down) and retracted (up) positions. The sidestand activates the sidestand switch (4) which is part of the starter interlock system. 2004 Buell P3: Chassis 2-69...
Page 149: Handlebars
Clutch lever and bracket assembly Clutch cable Switch, clutch lever 10. O-ring 11. Clamp 12. Left handlebar grip 13. Left switch assembly 14. Right switch assembly 15. Throttle grip 16. Brake lever switch a0133x2x Figure 2-119. Handlebar Assembly 2-70 2004 Buell P3: Chassis...
Page 150: Front And Rear Isolators
If seat is loose, it could shift during vehicle operation, causing loss of control of vehi- Figure 2-121. Front Isolator Bolts cle and death or serious injury. Install seat. See 2.28 SEAT. 2004 Buell P3: Chassis 2-71...
Page 151 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, causing loss of control of vehi- cle and death or serious injury. Install seat. See 2.28 SEAT. 2-72 2004 Buell P3: Chassis...
Page 152 HOME 7745 Figure 2-122. Frame-to-Isolator Bolts 7743 Rear isolator Bolts (4) Figure 2-123. Rear Engine Mount Isolator 2004 Buell P3: Chassis 2-73...
Page 153 Table Of Contents ENGINE SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 156: Specifications
2.105 in. (min) 53.467 mm (min) Intake 1.751-1.848 in. (closed) 72-92 lbs 33-42 kg 1.286-1.383 in. (open) 183-207 lbs 83-94 kg Exhaust 1.751-1.848 in. (closed) 72-92 lbs 33-42 kg 1.332-1.429 in. (open) 171-195 lbs 78-88 kg 2004 Buell P3: Engine...
Page 157 Table 3-8. Cylinder Head Speciﬁcations CYLINDER HEAD NEW COMPONENTS SERVICE WEAR LIMITS inches inches Valve guide in head (tight) 0.0033-0.0020 0.0838-0.0508 Valve seat in head (tight) 0.0035-0.0010 0.0889-0.0254 Head gasket surface (ﬂatness) 0.006 total 0.152 total 0.006 total 0.152 total 2004 Buell P3: Engine...
Page 158 SERVICE WEAR LIMITS Oil pressure 1000 RPM 7-12 PSI 48-83 KPa 2500 RPM 10-17 PSI 69-117 KPa Shaft to pump clearance 0.0025 in. 0.0635 mm Feed/scavenge inner/outer gerotor 0.003 in. 0.076 mm 0.004 in. 0.102 mm clearance 2004 Buell P3: Engine...
Page 159 Pinion shaft journal diameter 1.2496-1.2500 31.7398-31.7500 1.2496 (min) 31.7398 (min) Outer race diameter in right 1.5646-1.5652 39.7408-39.7561 1.5672 (max) 39.8069 (max) crankcase Bearing running clearance 0.00012-0.00088 0.00305-0.02235 Fit in cover bushing (loose) 0.0023-0.0043 0.0584-0.1092 0.0050 0.1270 2004 Buell P3: Engine...
Page 160 Swing arm pinch bolt 17-19 ft-lbs 23-26 Nm LOCTITE 243 (blue), Page 3-16 Swing arm pivot shaft 24-26 ft-lbs 32-35 Nm Page 3-16 Top rear tie bar 30-33 ft-lbs 41-45 Nm LOCTITE 262 (red), Page 3-22 2004 Buell P3: Engine...
Page 161: Engine
When an engine needs repair, it is not always possible to determine deﬁnitely beforehand whether repair is possible The Buell Blast P3 motorcycle has been designed to obtain with only cylinder head, cylinder and piston disassembled or the best performance and efﬁciency using unleaded gasoline whether complete engine disassembly is required for crank- (87 pump octane or higher).
Page 162: Diagnosing Smoking Engine Or High Oil Consumption
Valve guide seals. 35667A) and follow the speciﬁc instructions supplied with the tester. Valve guide-to-valve stem clearance. The following are some general instructions that apply to Buell motorcycle engines: Gasket surface of both head and cylinder. 2004 Buell P3: Engine...
Page 163: Stripping Motorcycle For Engine Service
NOT REMOVE”. See note above. NOTES For top end service proceed to step 11. For engine removal proceed to step 12. Figure 3-1. Remove Crankcase Breather Hose Figure 3-1. Remove crankcase breather hose and crankcase breather from rocker box grommet. 2004 Buell P3: Engine...
Page 164: Spacer
Remove entire air cleaner and carburetor as an assembly. 14. See Figure 3-5. Remove screws (4) on both air cleaner brackets (2,3). Figure 3-4. Remove Top Rear Tie Bar 13. See Figure 3-4. Remove top rear tie bar at frame. 2004 Buell P3: Engine...
Page 165 19. Place jack under the motor. Use jack to lower motor. Breather hose Three-way connector 20. Move jack forward. 21. Place wooden cradle under engine. Figure 3-7. Crankcase Breather Hose 16. See Figure 3-7. Remove crankcase breather hose. 3-10 2004 Buell P3: Engine...
Page 166 PORT BRACKETS. 24. Move belt on rear sprocket off pulley toward inside of 26. Introduce freeplay and remove clutch cable at hand lever motorcycle. location. See 1.10 CLUTCH. 2004 Buell P3: Engine 3-11...
Page 167 Located under seat (left side). Starter solenoid wire [128] Disconnect at starter. Spark plug wire Located on spark plug. Battery—positive wire Disconnect at main circuit breaker. Rear brake light switch [121] Located under frame by shock absorber. 3-12 2004 Buell P3: Engine...
Page 168 7718 7623 Figure 3-14. Removing Rear Motor Mount Bolts 32. See Figure 3-14. Remove rear motor mount bolts. Figure 3-12. Loosen Clamp 30. See Figure 3-12. Loosen nut on hose routing clamp. 2004 Buell P3: Engine 3-13...
Page 169 Lift chassis and roll away from engine. 7652 Figure 3-18. Swingarm Pivot Shaft Pinch Bolt 36. See Figure 3-18. Loosen swingarm pinch bolt. Figure 3-16. Air Cleaner Bracket 34. See Figure 3-16. Remove air cleaner box bracket. 3-14 2004 Buell P3: Engine...
Page 170 38. See Figure 3-20. Remove sidestand and bracket assem- bly. See 2.29 SIDESTAND. Figure 3-19. Swingarm Pivot Shaft 37. See Figure 3-19. Remove swingarm pivot shaft and rear wheel as an assembly. See 2.19 SWINGARM. 2004 Buell P3: Engine 3-15...
Page 171: Engine Installation
Tighten to 23-27 ft-lbs (31-37 Nm). Figure 3-22. Swingarm Pivot Shaft Figure 3-22. Install swingarm, pivot shaft and rear wheel as an assembly and tighten pivot shaft to 24-26 ft- lbs (32-35 Nm). See 2.19 SWINGARM. 3-16 2004 Buell P3: Engine...
Page 172 Apply several drops of LOCTITE 262 (red) to last Figure 3-26. Move Chassis to Engine few threads. Tighten to 30-33 ft-lbs (41-45 Nm). Figure 3-26. Roll chassis toward engine. Lift chassis onto engine. Raise lift. 2004 Buell P3: Engine 3-17...
Page 173 Tighten nut on hose routing clamp. crankcase vent lines. 16. Install rear shock. See 2.15 REAR SHOCK ABSORBER. 7635 Figure 3-30. Tighten Hose Clamps 14. See Figure 3-30. Tighten hose clamps using Hose Clamp Pliers (Part No. HD-41137). 3-18 2004 Buell P3: Engine...
Page 174 Located under seat (left side). Starter solenoid wire [128] Disconnect at starter. Spark plug wire Located on spark plug. Battery—positive wire Disconnect at main circuit breaker. Rear brake light switch [121] Located under frame by shock absorber. 2004 Buell P3: Engine 3-19...
Page 175 21. See Figure 3-32. Install master cylinder onto footpeg bracket. See 2.21 FOOTPEGS AND FOOTPEG SUP- PORT BRACKETS. Apply several drops of LOCTITE 243 (blue) to last few threads. Tighten to 48-72 in-lbs (5-8 Nm). 3-20 2004 Buell P3: Engine...
Page 176 Figure 3-37. Install and tighten screws on both air cleaner brackets. Right bracket to air cleaner, 36-60 in-lbs (4.1-6.8 Nm). Left bracket to crankcases, 120-144 in-lbs (13.6- 16.3 Nm). Install screw on air cleaner cover. 2004 Buell P3: Engine 3-21...
Page 177 60 ft-lbs (81.3 Nm). Figure 3-39. Install Front Tie Bar 30. See Figure 3-39. Install front tie bar onto engine. Apply several drops of LOCTITE 262 (red) to last few threads. Tighten to 30-33 ft-lbs (41-45 Nm). 3-22 2004 Buell P3: Engine...
Page 178 36. Remove jack from under the motor. 37. Install mufﬂer. See 2.20 EXHAUST SYSTEM. 38. Install fuel tank. See 4.2 FUEL TANK COVER/FUEL TANK. 39. Install new oil ﬁlter, engine oil and primary chaincase ﬂuid as necessary. 2004 Buell P3: Engine 3-23...
Page 179: 24. Push Rod
20. Gasket (push rod cover) 21. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-44. Rocker Arm and Push Rod Cover Assemblies 3-24 2004 Buell P3: Engine...
Page 180 Remove rocker arms, mark them for reassembly in their original locations. 10. Mark the location and orientation (top/bottom) of each push rod. Remove push rods. 2004 Buell P3: Engine 3-25...
Page 181 Mark valve to ensure that it will be reassembled in the same guide. Remove valve, valve stem seal and lower collar assembly. Repeat the above procedure for the other valve. Figure 3-48. Valve Spring Compressor (Part No. HD-34736B) 3-26 2004 Buell P3: Engine...
Page 182 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 Figure 3-49. Cylinder Head, Cylinder and Piston Assembly 2004 Buell P3: Engine 3-27...
Page 183 Never use a ﬁle or SERVICE WEAR LIMIT of 0.006 in. (0.152 mm). other hardened tool which could scratch or nick valve. Polish valve stem with very ﬁne emery cloth or steel wool. 3-28 2004 Buell P3: Engine...
Page 184 Figure 3-52. Measure where rocker arm bush- Check end play of rocker arm with feeler gauge. ings ride. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 2004 Buell P3: Engine 3-29...
Page 185: Valve Guides
If the seat is loose or is not fully seated in the head, then seat movement will prevent the proper transfer of heat from the valve. The seat surface must be ﬂush with (or below) the head surface. See 3.1 SPECIFICATIONS for valve seat-to-cylinder head ﬁt. 3-30 2004 Buell P3: Engine...
Page 186 Using remaining old bushing as a pilot, line ream new bushing with ROCKER ARM BUSHING REAMER (Part No. HD-94804-57). Repeat for other end of rocker arm. 8733 8734 Figure 3-57. Replacing Rocker Arm Bushings 2004 Buell P3: Engine 3-31...
Page 187 Figure 3-59. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. Valve guide remover/installer (Part No. B-45524) Cylinder head stand (Part No. HD-39782) Figure 3-58. Installing Shoulderless Valve Guide 3-32 2004 Buell P3: Engine...
Page 188 Clamp tool in vise and further tighten cylinder head onto the ﬁxture to prevent any movement during operation. Place cylinder head at a 45° angle or one that offers a comfortable working position. 2004 Buell P3: Engine 3-33...
Page 189 .062 in. (1.575 mm), pro- ceed to the next step. b0972x3x Intake & Exhaust Valve and Seat 60˚ Min. 0.040 in. (1.016 mm) Max. 0.062 in. (1.575 mm) Margin 31˚ 46˚ Figure 3-61. Valve and Seat Dimensions 3-34 2004 Buell P3: Engine...
Page 190 The keeper gaps should be CAUTION equal. Do not remove valve after seal is installed. Otherwise, 11. Release and remove VALVE SPRING COMPRESSOR. sharp edges on keeper groove will damage seal. 12. Repeat Steps 4-11 for the remaining valve. 2004 Buell P3: Engine 3-35...
Page 191 17984-00Y Orange (277.241 mm) CAUTION After head has been installed do not turn engine over until both push rods can be turned with ﬁngers. Other- wise, damage to push rods or rocker arms may result. 3-36 2004 Buell P3: Engine...
Page 192: Cylinder Head Installation
Tighten each screw to 96-120 in-lbs (11-14 Nm). Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-67. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all bolts an additional 85 -95 . 2004 Buell P3: Engine 3-37...
Page 193 20. Gasket (push rod cover) 21. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-68. Rocker Arm and Push Rod Cover Assemblies 3-38 2004 Buell P3: Engine...
Page 194 Place a new inner gasket on lower rocker box assembly. Place a new lower gasket on lower rocker cover. Install upper rocker cover using screws with washers and new ﬁber seals. Tighten screws to 120-168 in- lbs (13.6-9 Nm). 2004 Buell P3: Engine 3-39...
Page 195: Cylinder And Piston
Figure 3-70. Cylinder and Piston NOTE Since the piston pin is a loose ﬁt in the piston, the pin will eas- ily slide out. The pin has tapered ends to help seat the round retaining rings. 3-40 2004 Buell P3: Engine...
Page 196 Remove circlip from claw and discard. NOTE It is not necessary to remove both piston pin circlips during piston removal. Leave the second circlip in the pin bore. 2004 Buell P3: Engine 3-41...
Page 197 Lay a straightedge across the surface. Try to insert a feeler gauge between the straight- edge and the gasket surface. If cylinder base gasket surface is not ﬂat within 0.008 in. (0.203 mm), replace cylinder and piston. 3-42 2004 Buell P3: Engine...
Page 198 Record readings. This process will determine if cylinder is out-of-round and will also show any cylinder taper or bulge. Table 3-25. If cylinder is not scuffed or scored and is within service limit, see next section, FITTING PISTON RINGS. 2004 Buell P3: Engine 3-43...
Page 199: Boring And Honing Cylinder
After wiping the cylinder with a clean, oiled paper towel, the towel will be dark with contamination. Repeat this process using a new lightly oiled paper towel each time until the towel remains white. The cylinder is now clean. 3-44 2004 Buell P3: Engine...
Page 200 Replace ring if end gap exceeds speciﬁcation. If end gap is under speciﬁcation, ﬁling is permissible. Table 3-27. Piston Ring End Gap Ring Type inches Top compression ring 0.010-0.020 0.25-0.51 2nd compression ring 0.014-0.024 0.36-0.61 Oil control ring rails 0.010-0.050 0.25-1.27 2004 Buell P3: Engine 3-45...
Page 201 Figure 3-78. Ring End Gap Position Figure 3-78. 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. 3-46 2004 Buell P3: Engine...
Page 202 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 foreign material from falling into the crankcase. 2004 Buell P3: Engine 3-47...
Page 203 A loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair. a0102xSx Figure 3-85. Installing Piston Pin Retaining Ring 3-48 2004 Buell P3: Engine...
Page 204 Figure 3-88. Piston Support Plate (Part No. HD-42322) Figure 3-88. Turn engine until piston is resting on top of PISTON SUPPORT PLATE (Part No. HD-42322) top dead center. Lubricate cylinder wall, piston, pin and rod bushing with engine oil. 2004 Buell P3: Engine 3-49...
Page 205 HOME NOTES 3-50 2004 Buell P3: Engine...
Page 206: Lubrication System
The colder the weather, the shorter the recommended oil tion on checking oil level and changing oil and ﬁlter. change interval. A vehicle used only for short runs in cold weather must have the engine oil drained frequently. 2004 Buell P3: Engine 3-51...
Page 207: Oil Reservoir And Oil Hose Routing
Hose, oil drain Hose, oil return line 1/4 Spring clamp Hose, vent line Vent line elbow ﬁtting at gear cover Hose, oil feed line 10. T-ﬁtting 11. Dipstick Figure 3-90. Oil Reservoir and Hose Routing 3-52 2004 Buell P3: Engine...
Page 208 ﬁtting; the return hose connects forward and above. Figure 3-92. The drain hose attaches to the left side of the footpeg support bracket frame. Breather hose Oil drain hose Figure 3-92. Oil Drain Hose 2004 Buell P3: Engine 3-53...
Page 209: Oil Pressure Indicator Switch
MPH (80 KM/H) until engine oil reaches normal operating temperature. At 2500 RPM, oil pressure will vary from 10-12 psi (69-83 KPa). At idle speed (950-1050 RPM), oil pressure will vary from 6-8 psi (42-55 KPa). 3-54 2004 Buell P3: Engine...
Page 210: Crankcase Breathing System
Crankcase breather hose located behind the right footrest support (located by the oil Carburetor venturi tank drain hose). The crankcase breather drain hose should Figure 3-94. Crankcase Breathing System, be drained at each oil change. 2004 Buell P3: Engine 3-55...
Page 211: Oiling System
The return gears pump oil back to the oil reservoir. hydraulic lifters. Oil also enters an intersecting passage in the gearcase cover. Oil ﬂow is then routed to the crankshaft area. 3-56 2004 Buell P3: Engine...
Page 212: Oil Pump
Thrust washer Retaining ring Gerotor return set Separator plate 10. Gerotor feed set 11. Cover ° 12. 45 ﬁtting 13. Sems screw (2) 14. Torx screw (2) 15. Rear connector ﬁtting Figure 3-95. Oil Pump 2004 Buell P3: Engine 3-57...
Page 213 Remove and discard o-ring. Figure 3-95. Slide both pieces of gerotor feed set, separator plate and both pieces of gerotor scavenge set off gear shaft. Remove and discard retaining ring. Remove thrust washer and gear shaft. 3-58 2004 Buell P3: Engine...
Page 214 Gerotor separator plate Slot on separator plate Tab on oil pump body O-ring Figure 3-98. Separator Plate Slots Figure 3-98. Install gerotor separator plate by lining up slots on perimeter with tabs inside oil pump body. 2004 Buell P3: Engine 3-59...
Page 215: Oil Filter Mount
Apply several drops of LOCTITE 243 (blue) to last few threads on that end of the ﬁlter adapter (6) which is installed into ﬁlter mount (3). Do not apply LOCTITE to adapter threads on ﬁlter element side. 3-60 2004 Buell P3: Engine...
Page 216: Hydraulic Lifters
Figure 3-100. Lifter Assembly (Typical) End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. 2004 Buell P3: Engine 3-61...
Page 217 Tighten screws evenly to 30-40 in-lbs (3-5 Nm). Place new o-rings on top of push rod cover. Install push rods, cylinder head, lower and upper rocker covers. See 3.5 CYLINDER HEAD. 3-62 2004 Buell P3: Engine...
Page 218: Gearcase Cover And Cam Gears
Cam gear shaft outer bushing 10. Key 11. Gearcase cover gasket 12. Gearcase cover 13. Seal 14. Sems screw 15. Oil vent hose ﬁtting 16. Clamp 17. Vent hose 18. Outer bushing Figure 3-103. Gearcase Cover & Cam Assembly 2004 Buell P3: Engine 3-63...
Page 219 Blow out all cover oil passages and bushings with com- apart. Use GAUGE PIN SET (Part No. HD-38361) when mea- pressed air. suring pinion and cam gear sizes. Clean old gasket material from gearcase and cover faces with cleaning solvent. 3-64 2004 Buell P3: Engine...
Page 220 Table 3-29. Cam and Pinion Gear Color Code and Diameter GEAR NO. & POSITION INBOARD OUTBOARD COLOR CODE Intake Intake Exhaust Pinion (1 paint dot) 1.9025-1.9029 1.9025-1.9029 (48.323-48.333) (48.323-48.333) WHITE 1.9020-1.9024 1.9020-1.9024 (48.310-48.321) (48.310-48.321) GREEN 1.9015-1.9019 1.9015-1.9019 (48.298-48.308) (48.298-48.308) 2004 Buell P3: Engine 3-65...
Page 221 Figure 3-103. Install a new seal and new dry gear cover gasket on crankcase. 3-66 2004 Buell P3: Engine...
Page 222 Install cam position sensor and rotor in gearcase cover. 7.8 IGNITION MODULE AND CAM POSITION SEN- 7683 SOR. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-110. Checking Cam Gear End Play 2004 Buell P3: Engine 3-67...
Page 223: Crankcase
Replace bearing inner shim if difference (end play) in indicator readings is not 0.001-0.005 in. (0.025- 0.127 mm). Choose shim from Table 3-31. NOTE Use a thinner shim for less end play; use a thicker shim for more end play. 3-68 2004 Buell P3: Engine...
Page 224: Washer
Bottom case t40 TORX bolt (5) Washer (4) Hex socket head screw (1) Rear isolator Spacer (1) Dowel pin 10. Crankcase set Hex socket head screw (9) 11. Nyloc, hex locknut Washer (14) 12. Washer (1) Figure 3-112. Crankcase Hardware 2004 Buell P3: Engine 3-69...
Page 225 Oil seal Retaining ring Bearing assembly Gear shaft bearing Left crankcase half Retaining ring Connecting rod and ﬂywheel assembly Outer bearing race Inner race 10. Right crankshaft half Figure 3-114. Crankcase and Flywheel Assembly 3-70 2004 Buell P3: Engine...
Page 226 Pinion bearings are identiﬁed as Crankshaft bearing tool (Part No. HD-94547-101) shown. Left crankcase half Figure 3-116. Sprocket Outer Shaft Race Removal 12. See Figure 3-116. Use CRANKSHAFT BEARING TOOL (Part No. HD-94547-101) to remove sprocket shaft outer races. 2004 Buell P3: Engine 3-71...
Page 227 A - Roller OD cannot be measured to required accuracy with micrometer. Refer to color chart in Table 3-35. Figure 3-120. Bearing Identiﬁcation Table 3-34. Roller Speciﬁcations ROLLER OD (*A) IDENTIFICATION* Largest Blue White (Grey) Smallest Green 3-72 2004 Buell P3: Engine...
Page 228 1.145" (29.08 mm) 1.135" (28.83 mm) 1.272" (32.31 mm) 1.262" (32.05 mm) Figure 3-121. Pinion Shaft Bearing Tools 2004 Buell P3: Engine 3-73...
Page 229 Motor Company provides a ﬂywheel refurbishing program as outlined in Tech Tip #38. Always use the smallest outer race ID measurement and the largest OD inner race measurement when selecting bearings. 3-74 2004 Buell P3: Engine...
Page 230 1.2504 1.2506 1.2508 1.2510 1.2512 1.2514 1.2516 1.2518 31.740 31.745 31.750 31.755 31.760 31.765 31.770 31.775 31.780 31.786 3.791 31.745 31.750 31.755 31.760 31.765 31.770 31.755 31.780 31.786 31.791 31.796 FACTORY COLOR CODE Green White 2004 Buell P3: Engine 3-75...
Page 231 Lapping is completed when entire bushing surface has a dull, satin ﬁnish rather than a glossy, smooth appearance. If necessary, ﬂush off lap in cleaning solvent, air dry and apply fresh, light coat of ﬁne lapping compound. 3-76 2004 Buell P3: Engine...
Page 232 (2.8-4.0 Nm). Figure 3-125. Piston Oil Jet Assembly Figure 3-125. Remove two TORX screws from pis- ton jet assembly to remove piston jet from right crank- case. Remove piston jet gasket from right crankcase. 2004 Buell P3: Engine 3-77...
Page 233 Move snap ring if not properly centered. Loosen allen head screws and remove claws from snap ring. a0096x3x Figure 3-126. Snap Ring Installation Using Retaining Ring Remover/Installer (Part No. HD-44069) 3-78 2004 Buell P3: Engine...
Page 234 Position left outer race over bearing bore on outboard side of left crankcase half. Insert shaft of installer plug through left outer race and into installer base. Press race into bore until ﬁrmly seated against retaining ring. 2004 Buell P3: Engine 3-79...
Page 235 Slide sleeve over pilot until sleeve contacts inner bearing race. Install Nice bearing, washer and han- dle on top of sleeve. Rotate handle clockwise until bearing contacts ﬂy- wheel shoulder. Remove tool from sprocket shaft. 3-80 2004 Buell P3: Engine...
Page 236 BEARING INSTALLER (Part HD-42579) SPROCKET SHAFT SEAL INSTALLER (Part No. HD-45206) onto sprocket shaft. Follow procedure in Step 8. Rotate handle clockwise until the spacer makes contact with the bearing. Remove tool from sprocket shaft. 2004 Buell P3: Engine 3-81...
Page 237 Install the stud in the crankcase with the shoulder end down. Use an air gun to drive the stud until the shoulder reaches the crankcase. Remove air gun. Use a torque wrench to tighten stud to 10-20 ft-lbs (14-27 Nm). 3-82 2004 Buell P3: Engine...
Page 238 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Fuel Tank Cover/Fuel Tank .
Page 240: Fuel System
12-14 in-lbs 1-2 Nm Page 4-9 Tank cover to T-shaped bracket 30-36 in-lbs 3-4 Nm Page 4-6 Throttle position sensor 13-23 in-lbs 2-3 Nm Page 4-22 Vent tube ﬁtting 40-60 in-lbs 5-7 Nm Page 4-12 2004 Buell P3: Fuel System...
Page 241 Worn or damaged needle or needle jet. Replace assembly. Vacuum piston malfunction. Table 4-5. Plugged jets or passages. Clean and clear as required. 10. Fuel level too low. 10. Adjust ﬂoat tab for correct fuel level. 2004 Buell P3: Fuel System...
Page 242 Worn or damaged needle or needle jet. Replace assembly. Vacuum piston assembly malfunction. Table 4-5. Loose or plugged main jets or passages. Clean, clear and correct as required. 10. Improper fuel level. 10. Adjust ﬂoat level. 2004 Buell P3: Fuel System...
Page 243 Clean and clear passage. PISTON DOES NOT CLOSE PROPERLY Check for: Remedy: Spring damaged. Replace spring. Piston binding. Clean piston slides and body or replace piston. Piston diaphragm ring dirty or damaged. Clean or replace piston. 2004 Buell P3: Fuel System...
Page 244: Fuel Tank Cover/Fuel Tank
4.3 AIR CLEANER. Figure 4-3. Moving to front of vehicle, pry rubber stops from weld studs on each side of frame backbone. Raise rear of fuel tank and slide assembly rearward to remove from frame. 2004 Buell P3: Fuel System...
Page 245 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. Figure 4-1. Install seat. 2004 Buell P3: Fuel System...
Page 246 ﬁller cap over and either loosen or tighten the 10 mm nut (3). Bottom of fuel cap boot O-ring Figure 4-4. Fuel Cap 2004 Buell P3: Fuel System...
Page 247 “RES(ERVE)” position after refueling. a0176x4x Fuel supply valve Filter strainer Band clamp Fuel supply - “OFF” position Fuel supply - “ON” position Fuel supply - “RESERVE” position Figure 4-5. Fuel Supply Valve 2004 Buell P3: Fuel System...
Page 248 Remove o-ring from ﬂange of fuel valve assembly. Dis- card o-ring. Carefully unthread fuel ﬁlter strainer from fuel valve assembly. Clean strainer using a suitable solvent. Dis- card strainer if any damage is found. 2004 Buell P3: Fuel System...
Page 249 Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal. Drain fuel tank. See 1.21 FUEL SUPPLY VALVE AND FILTER STRAINER. Remove fuel ﬁller cap from tank. Post Check ball Figure 4-6. Rollover Valve 4-10 2004 Buell P3: Fuel System...
Page 250 Insert ﬁngers into ﬁller neck and under fuel cap boot to hold bottom of rollover valve. Rotate hex on vent tube ﬁt- ting in a counter-clockwise direction and remove. 2004 Buell P3: Fuel System 4-11...
Page 251 Hand tighten ﬁtting again and observe orientation of nozzle. If nozzle is closer, repeat pro- cedure. If further away, rotate body of valve in the opposite direction. A few attempts may be needed to achieve the desired result. 4-12 2004 Buell P3: Fuel System...
Page 252: Air Cleaner
13. Gasket, carburetor Spacer 14. Mounting bracket, right side Screw (2) 15. Rivet (2) Venturi ring 16. Screw (4) Air ﬁlter box 17. Air ﬁlter Breather hoses and ﬁttings 18. Screw Figure 4-10. Air Cleaner Assembly 2004 Buell P3: Fuel System 4-13...
Page 253: Carburetor
Remove Phillips screw (with lockwasher) to release Using a side cutters, cut clamp and remove fuel inlet stay plate on auto-enrichener from carburetor hous- hose from ﬁtting at side of carburetor. ing. Pull enrichener from carburetor bore. 4-14 2004 Buell P3: Fuel System...
Page 254 15. Adjust engine idle speed. See 1.20 IGNITION TIMING and using cable adjusters at handlebar, tighten cables as AND IDLE SPEED ADJUSTMENT. necessary to keep barrel ends from dislodging. Verify operation by turning throttle grip and observing cable action. 2004 Buell P3: Fuel System 4-15...
Page 255 ﬁt to ensure that the ﬂoat pin is securely held, so always tap out the pin in the direction of the cast-in arrow (that is, from the inter- ference side). 4-16 2004 Buell P3: Fuel System...
Page 256 Figure 4-13. Carburetor- Bottom End Figure 4-13. Remove ﬂoat (1) and fuel valve (3). Carefully slide clip (4) and fuel valve (3) from tab on ﬂoat (1). Remove wireform clip (4) from groove in fuel valve (3). 2004 Buell P3: Fuel System 4-17...
Page 257 ﬂoat bowl vent to blow carburetor cleaner out of holes in ﬂoat bowl chamber. 4-18 2004 Buell P3: Fuel System...
Page 258 Inspect fuel valve seat in carburetor housing for dirt, damage or corrosion. Replace carburetor if seat damage or corrosion is present. Verify cleanliness of slow jet. Be sure that all oriﬁces are clean and open. Replace jet if damaged. 2004 Buell P3: Fuel System 4-19...
Page 259 Install new o-ring into groove of ﬂoat bowl, if removed. Be sure to thoroughly clean groove before o-ring installa- tion. 10. Install four Phillips screws to secure ﬂoat bowl at bottom of carburetor body. Tighten screws until snug. 4-20 2004 Buell P3: Fuel System...
Page 260: Auto-Enrichener
At the end of its return stroke, the enrichener valve is open and the vehicle is ready for the next cold start. Enrichener valve Heater Wax and silicone contracted Air/Fuel passageway (closed position) Figure 4-18. Hot Start/Plunger is Closed 2004 Buell P3: Fuel System 4-21...
Page 261 Position seat on frame backbone, 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. 4-22 2004 Buell P3: Fuel System...
Page 262: Throttle Position Sensor
Figure 4-21. Throttle Position Sensor with O-ring Align holes in throttle position sensor with those in carbu- retor housing. Using special TORX bit (Snap-on® 2004 Buell P3: Fuel System 4-23...
Page 263: Evaporative Emissions Control System
ﬁtting is ﬁxed to an allen head screw on the venturi ring for positive location. Figure 4-22. Buell motorcycles sold in the state of Cali- Crankcase vapors passing through the PCV valve follow fornia are equipped with an evaporative (EVAP) emissions the fuel vapors to the charcoal canister via a 3-way ﬁtting...
Page 264 For correct assembly, mark tubes to correlate with stamps on canister. Mark one tube “CARB” and the other “TANK.” Pull PCV outlet hose (connection from carburetor throat and PCV valve) from ﬁtting at front of charcoal canister. 2004 Buell P3: Fuel System 4-25...
Page 265 3-way connector located inboard of the air box. along the inboard side above the oil drain hose. 4-26 2004 Buell P3: Fuel System...
Page 266 12. Oil drain hose Ignition coil 13. Breather drain hose Purge tube 14. Air box Ignition module connector 15. Charcoal canister hose Loop oil drain/return ﬁtting/hose 16. Breather hose Figure 4-26. Hose Routing (Left Side View) 2004 Buell P3: Fuel System 4-27...
Page 267 HOME NOTES 4-28 2004 Buell P3: Fuel System...
Page 268 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 271: Specifications
TORQUE VALUES ITEM TORQUE NOTES Battery terminal bolts 60-96 in-lbs 7-11 Nm Page 5-19 Starter battery positive cable nut 80-100 in-lbs 9-11 Nm Metric, Page 5-19 Starter mounting bolts 13-20 ft-lbs 18-27 Nm Page 5-19 2004 Buell P3: Electric Starter...
Page 272: Electric Starter System
(10) is reversed. The solenoid plunger (7) is returned to its original position by the return spring, which causes the pinion gear (1) to disengage from the clutch ring gear (13). 2004 Buell P3: Electric Starter...
Page 273 Armature Brush Ball bearing Solenoid plunger Main solenoid contacts Battery Starter 10. Pull-in winding during 11. Hold-in winding cranking 12. Overrunning clutch 13. Clutch ring gear Starting circuit see wiring diagram Figure 5-1. Starter Operation 2004 Buell P3: Electric Starter...
Page 274 Excessively worn teeth. Replace ring gear. Solenoid Return spring worn. Replace solenoid. Coil layer shorted. Contact plate melted and stuck. Starting Switch Unopened contacts. Replace starting switch or starter relay. or Starter Relay. Poor returning. 2004 Buell P3: Electric Starter...
Page 275: Starter Diagnostics
Battery voltage present? Ground. a0192x5x 5831 5832 5828 Replace right Repair wiring to handlebar starter button. Battery terminal switch gear. Motor terminal 5831 Continued on 5816 Next Page Figure 5-2. Starting System Diagnosis, Part 1 2004 Buell P3: Electric Starter...
Page 276 STARTER CURRENT DRAW TEST under 5.6 STARTER SYSTEM or Grounds. TESTING. Replace or repair starter motor. FREE RUNNING CURRENT DRAW TEST. 5817 See diagnostics in 7.11 STARTER/IGNITION INTERLOCK. Figure 5-3. Starting System Diagnosis, Part 2 2004 Buell P3: Electric Starter...
Page 277: Starter Activation Circuits
GROUND CIRCUIT 0.1A 0.1A 0.1A 0.1A 150A 150A 150A 150A Start switch Relay Solenoid Starter Battery Main circuit breaker Ignition switch Ignition circuit breaker Figure 5-4. Typical Circuity. (Refer to wiring diagrams for more information.) 2004 Buell P3: Electric Starter...
Page 278: Diagnostics/Troubleshooting
NOTE caused by the powdered paint will cause a voltage Open circuits on the ground side will read zero. drop or potential difference in the ground circuit. 2004 Buell P3: Electric Starter...
Page 279 2004 Buell P3: Electric Starter...
Page 280: Starter System Testing
Check for continuity between the 30 and 87 termi- nals. A good relay shows continuity (continuity tester lamp “on” or a zero ohm reading on the ohmmeter). A malfunctioning relay will not show continuity and must be replaced. 5-10 2004 Buell P3: Electric Starter...
Page 281: Starter
Push hoses to either side to allow access to starter. Remove nut with washer (metric) that attaches posi- tive battery cable to post. Remove positive battery cable ring terminal. Detach solenoid connector [128]. Remove starter and gasket. 2004 Buell P3: Electric Starter 5-11...
Page 282: Testing Assembled Starter
If starter pinion pulls in strongly, solenoid is working problem with engine or primary drive. properly. If starter pinion does not pull in, replace the sole- noid. 5-12 2004 Buell P3: Electric Starter...
Page 283 Motor terminal Observe starter pinion. Relay terminal If starter pinion remains in pull-in position, solenoid Figure 5-15. Return Test is working properly. If starter pinion does not remain in pull-in position, replace the solenoid. 2004 Buell P3: Electric Starter 5-13...
Page 284 0.008 in. (0.203 mm), use an undercutting machine End cover to undercut the mica to 0.031 in. (0.8 mm) deep. The slots should then be cleaned to remove any dirt or cop- Figure 5-17. Removing the Thru-Bolts per dust. 5-14 2004 Buell P3: Electric Starter...
Page 285 After undercutting, lightly sand the com- mutator with crocus cloth to remove any burrs. Figure 5-19. Mica must not be left with a thin edge next to segments. Mica must be cut away clean between segments. 2004 Buell P3: Electric Starter 5-15...
Page 286 Touch one probe to any commutator segment (1). Touch the other probe to the armature core (2). There should be no continuity (inﬁnite ohms). If there is continuity, then the armature is grounded. Replace grounded armatures. 5-16 2004 Buell P3: Electric Starter...
Page 287 Touch the other probe to each of the brushes attached to the ﬁeld coil(s) (2). 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. 2004 Buell P3: Electric Starter 5-17...
Page 288: 15. Gasket
Field wire nut with washer (metric) 20. Idler gear roller (5) Field wire 21. Idler gear 10. Armature bearing (2) 22. Ball 11. Armature 23. Return spring 12. Mounting bolt (2) 24. Solenoid housing Figure 5-26. Starter Assembly 5-18 2004 Buell P3: Electric Starter...
Page 289 Figure 5-27. Connect wiring to starter. Connect solenoid wire (2). Attach positive battery cable ring terminal (1) and install nut with washer (1) (metric). Tighten to 80- 100 in-lbs (9-11 Nm). Replace protective boot. 2004 Buell P3: Electric Starter 5-19...
Page 290: Gasket (Inner)
Replace wire connection hardware as Figure 5-29. Starter Solenoid necessary. Install plunger (5) in solenoid housing (6). Install new gasket (4) onto cover (3). Position cover with gasket onto solenoid housing. Install clip (2) and screws (1). 5-20 2004 Buell P3: Electric Starter...
Page 291 DRIVE/TRANSMISSION 6 Table Of Contents SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Chain .
Page 293: Specifications
Fifth gear (high) 4.74 * 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 drive rear wheel one revolution. 2004 Buell P3: Drive/Transmission...
Page 294 Bottom nut ﬁrst, same torque for top, Page 37 Transmission sprocket nut LOCTITE 262 (red), left hand threads, special See NOTES See NOTES torque turn method, Page 40 Transmission sprocket screws 90-110 in-lbs 10-12 Nm Replace after 3 removals, Page 40 2004 Buell P3: Drive/Transmission...
Page 295: Gasket (Lower Rocker Cover)
19. Oil seal 8. Primary cover 20. Rubber washer 9. Bushing 21. Splined collar 10. Spring 22. Pinch screw 11. Chain guide 23. Shift lever 12. Gasket 24. Coupling Figure 6-1. Primary Cover and Shifter Assembly 2004 Buell P3: Drive/Transmission...
Page 296 PEGS AND FOOTPEG SUPPORT BRACKETS. Remove three sems screws with washers and clutch inspection cover. Remove and discard gasket from groove in primary cover. 10. Slide spring with attached hex lockplate from ﬂats of clutch limiting screw. 2004 Buell P3: Drive/Transmission...
Page 297 CHAIN. Primary Chain Adjustment Figure 6-4. Buell Blast Models are shipped with a spacer between the primary chain limiting screw and the locknut. The Figure 6-5. Chain Limiting Screw-without Spacer spacer is used to quickly get proper adjustment during pro- duction.
Page 298 14. Install seat. See 2.28 SEAT. ring side of ramp assembly facing inward, place hook of ramp around coupling button and rotate assembly coun- terclockwise until tang on inner ramp ﬁts in slot of pri- mary cover. 2004 Buell P3: Drive/Transmission...
Page 299: Clutch Release Mechanism
Clutch cover gasket 13. Pin Spring 14. Shoe Lockplate 15. Screw 16. Locknut Ramp assembly 17. Limiting screw Primary cover 18. Drain plug and o-ring Bushing 19. Seal 10. Spring 20. Coupling Figure 6-8. Clutch Release Mechanism 2004 Buell P3: Drive/Transmission...
Page 300 Install seat. See 2.28 SEAT. Outer ramp Slot of primary cover Adjusting screw Cable end Coupling Figure 6-10. Nut & Outer Ramp 2004 Buell P3: Drive/Transmission...
Page 301: Primary Drive/Clutch
Worn clutch release ramps or balls. Replace release ramps and/or balls. Warped clutch steel plates. Replace clutch steel plates. Blade worn or damaged clutch gear splines. Replace clutch gear or hub as required. Overﬁlled primary. Drain lubricant to correct level. 2004 Buell P3: Drive/Transmission...
Page 302 Unseat spring seat (8) from the groove in clutch hub prongs. Remove pressure plate assembly (7). Figure 6-14. Remove the clutch pack from the hub/ shell assembly. The pack consists of ﬁve ﬁber plates and ﬁve steel plates. 6-10 2004 Buell P3: Drive/Transmission...
Page 303 21. Washer, labeled “out” Retaining ring 22. Clutch hub 10. Spring seat 23. Retaining ring 11. Diaphragm spring 24. Bearing 12. Retaining ring 25. Clutch shell and sprocket 13. Release plate 26. Retaining ring Figure 6-14. Clutch Assembly 2004 Buell P3: Drive/Transmission 6-11...
Page 304 Remove and discard small retaining ring and excessive wear. then separate the adjusting screw from the bearing Inspect stator and rotor. See 7.14 ALTERNATOR. and release plate. Remove bearing from release Replace damaged parts as necessary. plate. 6-12 2004 Buell P3: Drive/Transmission...
Page 305 If clutch shell was removed from motorcycle, check the bearing for smoothness. Rotate the clutch shell while holding the clutch hub. If bearing is rough or binds, it must be replaced. Figure 6-17. Measuring Friction Plates 2004 Buell P3: Drive/Transmission 6-13...
Page 306 With snap ring positioned against outboard side of spring seat, and fully seated in groove of clutch hub, carefully loosen and remove compression tool. 6-14 2004 Buell P3: Drive/Transmission...
Page 307 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 and startle the rider, causing loss of control and personal injury. Install seat. See 2.28 SEAT. 2004 Buell P3: Drive/Transmission 6-15...
Page 308 HOME NOTES 6-16 2004 Buell P3: Drive/Transmission...
Page 309: Transmission
Neutral 1st Gear Mainshaft Mainshaft Countershaft Countershaft 2nd Gear 3rd Gear Mainshaft Mainshaft Countershaft Countershaft 4th Gear 5th Gear Mainshaft Mainshaft Countershaft Countershaft – Sliding member – Power ﬂow Figure 6-23. Transmission Power Flow 2004 Buell P3: Drive/Transmission 6-17...
Page 310: Transmission Case
13. Remove detent screw (8), detent arm (7) and spring (11). Detent roller arm Spring Retention collar TORX screw Figure 6-24. Countershaft Retainer Figure 6-24. Place transmission in gear. Remove countershaft TORX screw (4) and retention collar (3). 6-18 2004 Buell P3: Drive/Transmission...
Page 311: Washer (2)
Figure 6-26. Crankcase Hardware 7694 Figure 6-27. Splitting Crankcase Halves 14. See Figure 6-26. Remove all transmission case bolts. 15. Remove rear isolator (3) and mounting hardware (1, 2). 16. See Figure 6-27. Separate crankcase halves. 2004 Buell P3: Drive/Transmission 6-19...
Page 312: Transmission Disassembly
REMOVER (2) (Part No. B-43985-1) to remove transmis- Figure 6-28. Transmission Assembly sion assembly from crankcase half. Figure 6-28. Remove transmission case. See Remove crankcase from ﬁxture. TRANSMISSION CASE Remove crankcase and transmission assembly from engine stand. 6-20 2004 Buell P3: Drive/Transmission...
Page 313 Detent screw 17. Shifter fork 1st & 2nd gear Detent plate 18. Shifter fork 3rd & 5th gear Retaining ring 19. Shifter fork drum 10. Shifter shaft assembly 20. Neutral indicator pin Figure 6-30. Shifter Mechanism 2004 Buell P3: Drive/Transmission 6-21...
Page 314 Fifth gear mainshaft Quad seal Bearing (outer) Spacer Oil seal 10. Oil seal Right crankcase half 11. Bearing (closed end) shifter drum Ball bearing 12. Bearing (closed end) countershaft Figure 6-32. Transmission Assembly Right Crankcase Half 6-22 2004 Buell P3: Drive/Transmission...
Page 315 17. 1st gear countershaft 18. Countershaft 19. 3rd gear countershaft 20. 2nd gear countershaft 21. 5th gear countershaft 22. Bearing 23. Retaining ring 24. Countershaft retainer 25. Screw Figure 6-33. Transmission Assembly Left Crankcase Half 2004 Buell P3: Drive/Transmission 6-23...
Page 316 1st gear (17). Remove retaining ring (11) and thrust washer (10). Slide countershaft 1st gear (17) off end of shaft. Remove split bearing (8). Remove thrust washer (10). Expand remaining retaining ring (11) and slide off countershaft (18). 6-24 2004 Buell P3: Drive/Transmission...
Page 317: Transmission Assembly
Install mainshaft 3rd gear (13) onto shaft over bearing ASSEMBLY. (8). Install thrust washer (10) and new retaining ring (11). 10. Install mainshaft 2nd gear (14) onto shaft with the fork groove facing 3rd gear(13). 2004 Buell P3: Drive/Transmission 6-25...
Page 318 17. 1st gear countershaft 18. Countershaft 19. 3rd gear countershaft 20. 2nd gear countershaft 21. 5th gear countershaft 22. Bearing 23. Retaining ring 24. Countershaft retainer 25. Screw Figure 6-34. Transmission Assembly Left Crankcase Half 6-26 2004 Buell P3: Drive/Transmission...
Page 319 Secure pins in place with new cotter pins. Align shifter fork assembly with transmission gear fork grooves. NOTE This completes transmission assembly. Transmission compo- nents are now prepared for installation into the left crankcase half. 2004 Buell P3: Drive/Transmission 6-27...
Page 320 Detent screw 17. Shifter fork 1st & 2nd gear Detent plate 18. Shifter fork 3rd & 5th gear Retaining ring 19. Shifter fork drum 10. Shifter shaft assembly 20. Neutral indicator pin Figure 6-36. Shifter Mechanism 6-28 2004 Buell P3: Drive/Transmission...
Page 321: Main Drive Gear
(2). Install and tighten nut (6) until 5th gear (3) is free. b1069x6x Cross plate Bolt 5th gear Driver Thrust washer Figure 6-39. Removing Main Drive Gear Main drive gear Needle bearing (2) Seal Figure 6-37. Main Drive Gear Assembly 2004 Buell P3: Drive/Transmission 6-29...
Page 322 (4) bottoms against inner race of bearing. Thrust washer Bolt Figure 6-37. Tap in new seal (3) at threaded end of Installer cup 5th gear. 5th gear Washer Figure 6-41. Main Drive Gear Installation 6-30 2004 Buell P3: Drive/Transmission...
Page 323: Bolt (4)
The bearing is properly positioned when driven inward ﬂush or 0.030 in. (0.762 mm) below the outside surface. Lubricate bearing with Sport-Trans Fluid. 2004 Buell P3: Drive/Transmission 6-31...
Page 324 Fifth gear mainshaft Quad seal Needle bearing (2) Spacer Oil seal 10. Oil seal Right crankcase half 11. Bearing (closed end) shifter drum Ball bearing 12. Bearing (closed end) countershaft Figure 6-44. Transmission Assembly Right Crankcase Half 6-32 2004 Buell P3: Drive/Transmission...
Page 325: Left Crankcase Bearings
ﬂush with or 0.020 in. (0.508 mm) below inside surface. If using a pressing tool larger than diameter of bushing, the pressing tool will bottom against crankcase when bushing is ﬂush with top surface. 2004 Buell P3: Drive/Transmission 6-33...
Page 326 17. 1st gear countershaft 18. Countershaft 19. 3rd gear countershaft 20. 2nd gear countershaft 21. 5th gear countershaft 22. Bearing 23. Retaining ring 24. Countershaft retainer 25. Screw Figure 6-47. Transmission Assembly Left Crankcase Half 6-34 2004 Buell P3: Drive/Transmission...
Page 327: Transmission Installation
Tighten 5/16-in. fasteners to 15-19 ft-lbs (20- sion assembly install TRANSMISSION 25 Nm). INSTALLER (Part no. B-43985-3) into crankcase. Figure 6-49. Press crankcase into transmission assembly until it bottoms out. Remove transmission assembly and left crankcase half from ﬁxture. 2004 Buell P3: Drive/Transmission 6-35...
Page 328 Bottom case t40 TORX bolt (5) Washer (4) Hex socket head screw (1) Rear isolator Spacer (1) Dowel pin 10. Crankcase set Hex socket head screw (9) 11. Nyloc, hex locknut Washer (14) 12. Washer (1) Figure 6-51. Crankcase Hardware 6-36 2004 Buell P3: Drive/Transmission...
Page 329: Shifter Pawl Adjustment
(1) ﬁrst to 90-110 in-lbs (10-12 Nm). Attach loop of spring (11) over and into groove in pin (6). Then, tighten shifter shaft assembly top locknut (1) to the same torque. Remove drill bit. 2004 Buell P3: Drive/Transmission 6-37...
Page 330 Apply several drops of LOCTITE 243 (blue) to last Spring few threads. Insert screw (1) through retention collar (2) and Figure 6-54. Countershaft Retainer thread into end of shaft. Place transmission in gear, and tighten TORX screw (1) to 13-17 ft-lbs (18-23 Nm). 6-38 2004 Buell P3: Drive/Transmission...
Page 331: Transmission Sprocket
Figure 6-55. Remove transmission sprocket nut (3) from main drive gear shaft (1). Figure 6-56. Install SPROCKET HOLDING TOOL Figure 6-56. Secure pulley using SPROCKET (1) (Part No. B-43982) as shown. LOCKING TOOL (Part No. B-43982). 2004 Buell P3: Drive/Transmission 6-39...
Page 332 Tighten the transmission sprocket nut an additional 30°- 40°. Figure 6-55. Install lockplate over nut so that two of lockplate’s four drilled holes (diagonally opposite) align with sprocket’s two tapped holes. 6-40 2004 Buell P3: Drive/Transmission...
Page 333 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 335: Specifications
67713-86 Marker lamps Tail/Stop Lamp 5/21 0.42/1.75 Y0401B.2U Turn Signal Lamp, Front and Rear 0.83 68968-99Y (1 bulb each) High Beam Indicator, Turn Signal Indicator Non-replaceable LEDs Indicator lamps (in speedometer) Oil Pressure Indicator, Neutral Indicator 2004 Buell P3: Electrical...
Page 336 25-28 in-lbs 2.8-3.2 Nm metric, Page 7-51 Throttle position sensor fasteners 12-23 in-lbs 1.4-2.6 Nm Page 7-12 Timing inspection hole plug 10-15 ft-lbs 13.6-20.3 Nm Page 7-21 Voltage regulator mounting fasteners 48-72 in-lbs 5.4-81 Nm Page 7-43 2004 Buell P3: Electrical...
Page 337: Ignition System
Timer cover Module plate (ignition module/cam position sensor) Rotor cup Spark plug Spark plug cable Ignition coil Connector [88] Auto-enrichener Throttle position sensor (TP sensor) 10. Connector [10] 11. Bank angle sensor Figure 7-1. Ignition System Components 2004 Buell P3: Electrical...
Page 338 The ignition system produces a spark near top dead center (TDC) for starting. At RPM’s and loads above this, the system produces a spark 0˚-45˚ before TDC. The whole timing pro- gram can be shifted by mechanical rotation of the integrated Figure 7-2. Test Jumper 2004 Buell P3: Electrical...
Page 339 2004 Buell P3: Electrical...
Page 340: Diagnostic Charts
Repair / Replace Engine Stop Switch Coil and [22A]. or Wiring. 5002 5173 Wire Harness Connectors Description Type Location [22] RT Handlebar Switch 4 - Place Multilock Behind Headlight Figure 7-4. No Spark At Spark Plug 2004 Buell P3: Electrical...
Page 341 Go To Next Page Use harness connector adaptor kit (HD-41404) gray female Repair Open Between [10B] Pin 6 Repair Open In W/BK Wire probe(s) and patch cord. (BK) And Ground 5003 5003 Figure 7-5. No Spark At Spark Plug 2004 Buell P3: Electrical...
Page 342 Inspect For Mechanical Failure. 5009 Repair. 5005 Inspect ignition module for signs of physical contact with rotor cup. Replace rotor cup if necessary. 7793 Connector [10] Coil Harness Adapters (HD-42962) Figure 7-6. No Spark At Spark Plug 2004 Buell P3: Electrical...
Page 343 Repair short to ground on LT Inspect module harness GN/GY wire. for damage. Repair if necessary. 5007 If harness is not damaged, replace ignition module. Connector [134] 8261 Figure 7-7. Continuous or No Spark At Spark Plug 2004 Buell P3: Electrical...
Page 344 Are Ferrous Metals Located Within 0.250 in. (6.4 mm) Install Properly. Of Sides, Face, Or Top Of Bank Angle Sensor? Return To Original Replace Bank Angle Sensor. Configuration. 5013 Figure 7-8. Continuous or No Spark At Spark Plug 7-10 2004 Buell P3: Electrical...
Page 345 Check continuity between breakout box Pin 3 and connector [88B] pins 3 and 4. 7610 Continuity present? Replace TP Sensor. Repair Open. 7590 7580 Remove seat and fuel tank cover. See 2.28 SEAT. Figure 7-9. Drivability Troubleshooting 2004 Buell P3: Electrical 7-11...
Page 346: Throttle Position Sensor (Tp Sensor)
After WOT, the TPS reading may not return back to exactly Black TP Sensor Ground 0.5V +/- 0.05V. To re-check exact TPS voltage reading, turn cycle key off and on. Not Used Tighten TP Sensor mounting screws to 13-23 in-lbs (2-3 Nm). 7-12 2004 Buell P3: Electrical...
Page 347: Bank Angle Sensor
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. Install seat. See 2.28 SEAT. 2004 Buell P3: Electrical 7-13...
Page 348: Ignition/Headlamp Key Switch
Replace the unit if it fails. Switch positions are explained in Table 7-11. Table 7-11. Ignition Switch Labeling REMOVE LABEL NAME IGN. LAMPS LOCK Fork Lock Park See note & Table 7-12. Ignition 7-14 2004 Buell P3: Electrical...
Page 349 Cut cable tie and disconnect ignition key switch connector [33] from main wiring harness. Note location of cable tie. Remove two headlight bucket bolts and headlamp bucket. See 7.17 HEADLAMP. Remove two bolts and ignition key switch. 2004 Buell P3: Electrical 7-15...
Page 350: Auto Enrichener
Table 7-14. Figure 7-15. Throttle Position Sensor Table 7-14. Electrical Connector [88] CHAMBER WIRE COLOR FUNCTION NUMBER Violet/Orange Auto-Enrichener Orange Auto-Enrichener Light Blue TP Sensor Output Yellow TP Sensor Input Black TP Sensor Ground Not Used 7-16 2004 Buell P3: Electrical...
Page 351 7505 7516 Replace fuse. Locate and repair Short to Use black male probe and patch cord from ground on Orange wire. TEST CONNECTOR KIT (Part No. HD-41404). 7517 Replace fuse. 7510 Figure 7-16. Driveability Troubleshooting 2004 Buell P3: Electrical 7-17...
Page 352: Ignition Module And Cam Position Sensor
Figure 7-18. Drill hole in outer timer cover at 5:00 position approximately 0.500 in. (13 mm) in from outside edge. Pull out outer timer cover using 90 degree pick or other suitable tool. 7-18 2004 Buell P3: Electrical...
Page 353 10r12 spark plug Spark plug cable Ignition coil Connector [88] 10. Auto-enrichener 11. Tamper-resistant T20 TORX screws 12. Throttle position sensor (TP sensor) 13. Connector [10] 14. Bank angle sensor Figure 7-19. Ignition System Components 2004 Buell P3: Electrical 7-19...
Page 354 If seat is loose, it could shift *Tan/Yellow [10B] during vehicle operation and startle the rider, causing Black Ground loss of control of vehicle and result in death or serious injury. 12. Install seat. See 2.28 SEAT. 7-20 2004 Buell P3: Electrical...
Page 355 Figure 7-18. Drill hole in location shown and remove outer timer cover, if not removed. Loosen module plate screws just enough to allow sensor plate to be rotated using a screwdriver in the plate's notch. 2004 Buell P3: Electrical 7-21...
Page 356 (counter-clockwise) until front intake valve opens and closes. Figure 7-22. Rotate rear wheel from right side of vehicle in direction of forward motion (clockwise) until TDC mark (vertical line) is centered in timing inspection hole. 7-22 2004 Buell P3: Electrical...
Page 357: Ignition Coil
See DIAGNOSTIC CHARTS. Check for primary coil winding resistance. Normal resistance range is 0.4-0.6 ohms. TEST RESULTS on the next page if resistance is not within normal operating range. 2004 Buell P3: Electrical 7-23...
Page 358 (-) To Ignition Module Attach left side cover. Install negative battery cable to battery terminal. Tighten Black Ground fastener to 60-96 in-lbs (6.8-10.8 Nm). Install fuel tank cover. See 4.2 FUEL TANK COVER/ FUEL TANK. 7-24 2004 Buell P3: Electrical...
Page 359 Replace cables not meeting resistance speciﬁcations of 2375-5833 ohms. INSTALLATION Connect spark plug cable to ignition coil and spark plug. Fasten boot/cap securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. 2004 Buell P3: Electrical 7-25...
Page 360: Starter/Ignition Interlock
This system will prevent vehicle operation if for- ward motion is attempted with the sidestand down. 7.3 DIAGNOSTIC CHARTS for Ignition Tests. NOTE Use gray male probe and patch cord from TEST CONNEC- TOR KIT (Part No. HD-41404). 7-26 2004 Buell P3: Electrical...
Page 361 Ground present? Replace diode. Repair open on TN wire Replace 5062 Diode installed between neutral switch neutral backwards. and Diode 1. switch. Reverse polarity. 5061 5063 5064 Figure 7-31. Ignition Test 2 2004 Buell P3: Electrical 7-27...
Page 362 [95] and Diode 2. 5073 Replace clutch Repair open on Diode installed Replace switch. BK wire between backwards. diode. connector [95] and Reverse polarity. 5074 ground. 5072 5071 5075 Figure 7-32. Ignition Test 3 7-28 2004 Buell P3: Electrical...
Page 363 2004 Buell P3: Electrical 7-29...
Page 364: Sidestand Switch
Depress clutch lever and hold. Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar. Install new switch. NOTE To test/replace the neutral switch, see 7.23 NEUTRAL INDI- CATOR SWITCH. 7-30 2004 Buell P3: Electrical...
Page 365 Bracket loss of control of vehicle and result in death or serious Screw injury. Nut with lock washer (2) Acorn nut (2) Install seat. See 2.28 SEAT. Figure 7-38. Circuit Breaker Installation 2004 Buell P3: Electrical 7-31...
Page 366 The reference numbers below correlate with the circled num- bers in the 7.11 STARTER/IGNITION INTERLOCK ﬂow charts. a0235x7x Continuity Infinite ohms Figure 7-40. Ohmmeter Diode Test Check diode with an ohmmeter as shown in Figure 7-40. 7-32 2004 Buell P3: Electrical...
Page 367: Diodes
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control of vehicle and death or serious injury. Install seat. See 2.28 SEAT. 2004 Buell P3: Electrical 7-33...
Page 368: Charging System
Check by using an ohmmeter with one lead on a known good ground, such as battery ground cable, and the other on the regulator base. Connector plug to stator must be clean and tight. 7-34 2004 Buell P3: Electrical...
Page 369 5319 2. Accessories on when vehicle is ridden very slowly for long periods. 3. Battery self-discharge and/or accessory draw because vehicle was not operated for a long period. Figure 7-44. Charging System Troubleshooting 2004 Buell P3: Electrical 7-35...
Page 370 BROWN GREEN PIN CONNECTOR GRAY ORANGE SOCKET CONNECTOR PINK SPLICE CONNECTION VIOLET NO CONNECTION WHITE YELLOW Voltage Regulator Main Circuit Breaker BK 2 Starter BK 3 BK 3 Battery Stator Figure 7-45. Charging System Circuit 7-36 2004 Buell P3: Electrical...
Page 371 The current output should exceed current draw by 3.5 amps minimum. If output does not meet speciﬁcations, there may be too many accessories for the charging system to handle. Reconnect regulator after testing. Replace cut cable strap. 2004 Buell P3: Electrical 7-37...
Page 372 Test for resistance with ohmmeter set on the RX1 scale. Resistance across the stator sockets should be 0.2- 0.4 ohms. If the resistance is lower, the stator is damaged and must be replaced. Figure 7-50. Check for Stator Resistance 7-38 2004 Buell P3: Electrical...
Page 373 If output is good, charging problem might be faulty regulator/rectiﬁer. Replace as required. Check the output again as described under Current and Voltage Output Test. a0245x7x Figure 7-51. Check Stator AC Voltage Output 2004 Buell P3: Electrical 7-39...
Page 374: Alternator
Figure 7-53. Position blocking under rotor. Press sprocket free of rotor. NOTE 7805 Resistance to sprocket/rotor disassembly is due in part to the magnetic force of the permanent rotor magnets. Figure 7-52. Rotor Assembly 7-40 2004 Buell P3: Electrical...
Page 375 Loss of torque on TORX fasteners could result in alternator damage. Remove stator wiring grommet from left crankcase half. Withdraw stator wiring from grommet hole in left crank- case half. Remove stator. 2004 Buell P3: Electrical 7-41...
Page 376 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control of vehicle and death or serious injury. 11. Install seat. See 2.28 SEAT. 7-42 2004 Buell P3: Electrical...
Page 377: Voltage Regulator
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control of vehicle and death or serious injury. Install seat. See 2.28 SEAT. 2004 Buell P3: Electrical 7-43...
Page 378: Battery
See Figure 7-59. All 2004 Model Year Buell batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.
Page 379: Battery Testing
ON could cause a spark resulting in a battery explosion which could result in death or serious injury. Install the battery on the motorcycle. See BATTERY INSTALLATION AND CONNECTION. 2004 Buell P3: Electrical 7-45...
Page 380: Disconnection And Removal
Turn the charger “OFF” before connecting the leads motorcycle parts. to the battery to avoid dangerous sparks. Never try to charge a visibly damaged or frozen bat- Install the battery on the motorcycle. See BATTERY tery. INSTALLATION AND CONNECTION. 7-46 2004 Buell P3: Electrical...
Page 381 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, causing loss of control of vehi- cle and death or serious injury. Install seat. See 2.28 SEAT. 2004 Buell P3: Electrical 7-47...
Page 382 Figure 7-62. Battery Self-Discharge Rate 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). 7-48 2004 Buell P3: Electrical...
Page 383: Headlamp
Install bracket with two allen screws and tighten to 12-14 ft lbs (16.3-19.0). Repeat for other bracket Attach both front turn signals. See 7.19 TURN SIG- NALS. Install windscreen if removed with four screws and washers. See 2.26 WINDSCREEN. 2004 Buell P3: Electrical 7-49...
Page 384 Check for proper headlamp operation before riding Align headlamp. See 1.23 HEADLAMP. motorcycle. Visibility is a major concern for motorcy- clists. Failure to have proper headlamp operation could result in death or serious injury. 7-50 2004 Buell P3: Electrical...
Page 385: Tail Lamp
Squeeze front brake hand lever. Check for brake lamp illumination. Release front brake hand lever. Press rear brake pedal. Check for brake lamp illumi- nation. Release rear brake pedal. Turn ignition key switch to OFF. 2004 Buell P3: Electrical 7-51...
Page 386: Turn Signals
Front and rear left turn signals must ﬂash. Activate right turn signals using switch on left han- Lockwasher & screw dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. Figure 7-68. Rear Turn Signals 7-52 2004 Buell P3: Electrical...
Page 387 Front and rear left turn signals must ﬂash. Left rear directional lamp Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Figure 7-69. Rear Turn Signal Connections Turn ignition key switch to OFF. 2004 Buell P3: Electrical 7-53...
Page 388: Turn Signal Flasher
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control of vehicle and death or serious injury. Install seat. See 2.28 SEAT. 7-54 2004 Buell P3: Electrical...
Page 389: Handlebar Switches
Figure 7-72. Right Handlebar Switches Figure 7-72. Check handlebar switch for proper operation. If operation fails, reread procedure and verify that all steps were performed. Turn ignition key switch to IGN. Start motorcycle. Turn ignition key switch to OFF. 2004 Buell P3: Electrical 7-55...
Page 390 Activate horn by pressing horn switch. Turn ignition key switch to OFF. Figure 7-73. Left Handlebar Switch Connection [24] and Clutch Switch Connection [95] 7079 Passing lamp HIGH beam LOW beam Turn signals Horn Figure 7-74. Left Handlebar Switches 7-56 2004 Buell P3: Electrical...
Page 391: Horn
If horn is faulty, replace unit as an assembly. The horn is not repairable. If battery voltage is not present, either horn switch or wiring to horn is faulty. If horn switch is faulty, replace left handlebar switch. See 7.21 HANDLE- SWITCHES. 2004 Buell P3: Electrical 7-57...
Page 392: Neutral Indicator Switch
Install switch in crankcase. Tighten to 36-60 in-lbs (4.0-6.8 Nm). Connect wire lead to switch. Install transmission sprocket (4) (with secondary drive belt) onto main drive gear shaft (3). See 6.14 TRANS- MISSION SPROCKET. Install sprocket cover. See 2.22 SPROCKET COVER. 7-58 2004 Buell P3: Electrical...
Page 393: Fuses And Circuit Breakers
Lights 15A Key switch 15A Always investigate the cause of blown fuses before replacing System 15A them. See your Buell dealer for more information. Spare (2) Ignition 7.5A Circuit Breakers Accessory 7.5A Figure 7-79.
Page 394: Electronic Speedometer
If the trip switch is pressed for more than 5 seconds at any time while in the diagnostic Install rubber boot/bezel assembly to odometer reset mode, the diagnostic code displayed will be erased. switch. 7-60 2004 Buell P3: Electrical...
Page 395 Remove two screws that secure speedometer to rear of dash panel. Apply more glass cleaner in gap and work speed- ometer free from dash. Depress tab and remove speedometer connector [39]. 2004 Buell P3: Electrical 7-61...
Page 396: Speedometer Sensor
If seat is loose, it could shift during vehicle operation, causing loss of control of vehi- cle and death or serious injury. Speedometer sensor Install seat. See 2.28 SEAT. Screw Figure 7-84. Speedometer Sensor 7-62 2004 Buell P3: Electrical...
Page 397: Speedometer Performance Check
To change the test frequency, press CLEAR to cancel and enter the new fre- quency. Press ENTER to begin and reverify. NOTE The speedometer should be accurate within 0-4 MPH (0- 6.5 KPH). 2004 Buell P3: Electrical 7-63...
Page 398 Sweep tool has frequency jumps in full scale sweeps. Perform sweep in 3 stages as described in speedometer tester manual. a0263x7x 10. Disconnecting speed sensor or install speedometer sen- Figure 7-87. Test Harness sor will cause code d02 to set. 7-64 2004 Buell P3: Electrical...
Page 399 Speedometer Test: Chart Replace Place jump wire across boot. leads to reset switch on back of speedometer. 6002 Does display toggle between modes? Replace Replace reset switch. speedometer. 6001 6020 Figure 7-88. Speedometer Test Chart 1 2004 Buell P3: Electrical 7-65...
Page 400 Outputs erratic? Repair as Replace necessary. speedometer. 6004 6006 Bad connection found. Repair con- nector or harness. 6008 STOP Go to Speedometer Test: Chart Figure 7-89. Speedometer Test Chart 2A 7-66 2004 Buell P3: Electrical...
Page 401 6008 damaged. Does damage exist? Repair as Check speedometer speed necessary. sensor. Clean or replace sen- sor as required. Retest. 6016 Problem solved? System OK. Replace speedometer. 6029 6024 Figure 7-90. Speedometer Test Chart 2B 2004 Buell P3: Electrical 7-67...
Page 402: Indicators
High Beam Indicator 12V When Active Black Right/Left Turn/High Beam R/L Turn Indicator 12V When Active Not Used Not Used Sensor Power White Sensor Return Black Sensor Ground Not Used Not Used Figure 7-91. Diagnostics 7-68 2004 Buell P3: Electrical...
Page 403: Main Wiring Harness
10. Tag and disconnect right and left front turn signal bullet connectors. 11. Disconnect ignition switch connector [33]. 12. Note location of cable strap and cut cable strap on horn wire and remove two blade connectors [122] from horn. 2004 Buell P3: Electrical 7-69...
Page 404 23. Disconnect side stand switch connector [60] above swing 32. Pull main wiring harness out through rear of frame. arm. 24. Disconnect oil pressure switch connector [120]. 25. Disconnect rear brake line switch connector [121] located above swingarm on right side of motorcycle. 7-70 2004 Buell P3: Electrical...
Page 405 15-18 in-lbs (1.7-2 Nm). Tighten plastic acorn nut bundles. to 1-3 in-lbs (0.1-0.3 Nm). Feed negative (-) wire across frame and connect to volt- age regulator mount and frame. Use two cable straps to secure wires. 2004 Buell P3: Electrical 7-71...
Page 406 Failure to have proper tail lamp, turn signal and/or headlamp operation could result in death or serious injury. 33. Check for proper operation of headlamp, turn signals, brake lamp and starting, charging and ignition systems. 7-72 2004 Buell P3: Electrical...
Page 407 Table Of Contents SUBJECT PAGE NO. A.1 Tools ............B.1 Electrical Connectors .

Buell Blast 2014 Service Manual

Maintenance 1

Chassis 2

Table of Contents

Engine 3

Table of Contents

Fuel System 4

Electric Starter 5

Drive/Transmission 6

Electrical 7

Quick Links

Chapters

Troubleshooting

Related Manuals for Buell Blast 2014

Summary of Contents for Buell Blast 2014