Buell 2002 P3 Service Manual page 244

HOME
Bottom End Components
1. Thoroughly clean all loose parts with carburetor cleaner.
See Figure 4-18. Blow dry using low pressure com-
pressed air.
11 1
WARNING
Compressed air can pierce the skin and cause injury.
Never use your hand to check for leaks or to determine
air flow rates. Wear safety glasses to shield your eyes
from flying dirt and debris. Failure to comply could result
in death or serious injury.
2. Inspect parts as follows:
a. Inspect O-ring in groove of float bowl for cuts, tears
or signs of deterioration. Replace O-ring if distorted
or if sealing surface is damaged.
b. Inspect float pin for damage or distortion. Replace
float pin if corroded, nicked or bent.
c. Clean float and inspect for cracks or other damage.
Submerge float in a glass of water. Replace float if
not water tight.
d. Depress pin on fuel valve to verify that it returns to
the full-out position. Thoroughly clean valve with car-
buretor cleaner if pin is dirty or sticks. Inspect rubber
cone on valve for dirt, cracks, hardening or wear.
Inspect wireform clip for distortion. Replace fuel
valve assembly if any of these conditions are found.
e. Inspect fuel valve seat in carburetor housing for dirt,
damage or corrosion. Replace carburetor if seat
damage or corrosion is present.
f. Verify cleanliness of slow jet. Be sure that all orifices
are clean and open. Replace jet if damaged.
Verify cleanliness of main jet, needle jet holder and needle
jet. Verify that orifices in needle jet holder are clean and open.
Replace parts if damaged.
WARNING
ASSEMBLY - TOP END
1. Install vacuum piston into carburetor body. Slides on pis-
ton are offset, so piston will fit into slide track groove only
one way. If vacuum piston does not fit, rotate assembly
°
180 .
2. Insert jet needle into vacuum piston bore, so that it
enters center hole at bottom. In the installed position,
head of needle contacts boss at bottom of vacuum pis-
ton bore, while length of shaft resides in main jet bore.
3. With the legged side down, slide spring seat over top of
needle in vacuum piston bore. Slide spring over spring
seat.
4. Verify that lip on edge of diaphragm is seated in groove
of carburetor flange.
NOTE
Diaphragm expands when in contact with fuel. If diaphragm is
difficult to seat in groove because of this condition, allow dia-
phragm to dry before attempting to install.
5. Fit free end of spring over boss on inboard side of carbu-
retor top, and keeping spring straight, align holes in top
with those in flange.
6. Holding top to flange, check for proper diaphragm seal
by pushing up on vacuum piston (from intake side) and
releasing. If diaphragm is sealed correctly, very slight
resistance should be felt when pushing up, and piston
should be slow to extend. If piston movement is
restricted, spring is cocked. Lift up on top and then lower
carefully keeping spring coils straight.
7. Install three black top screws in holes furthest from throt-
tle wheel. Alternately tighten screws until snug.
8. Slide gold top collar into remaining hole in carburetor top.
With end of idle screw resting on top of throttle cam stop,
align holes in throttle cable bracket with those in carbure-
tor body and top cover. To prevent bending bracket or
throttle cam, first install gold Phillips screw (with lock-
washer) at side of carburetor. At carburetor top, install
remaining Phillips screw.
2002 Buell P3: Fuel System 4-19