Buell 2002 P3 Service Manual page 54

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DRIVE BELT AND REAR SPROCKET
REPLACEMENT
1. Remove seat. See 2.28
11 1
WARNING
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
2. Disconnect the negative battery cable from the battery.
3. Raise rear wheel off floor using REAR WHEEL SUP-
PORT STAND (Part No. B-41174).
4. See Figure 1-19. Place rod or screwdriver through axle
hole. Loosen rear axle nut (1) (metric).
5. Remove nut, lockwasher, and flat washer.
6. Pull axle out. Remove right side spacer.
7. Slide carrier with caliper off rotor.
8. Remove left side spacer.
9. Move wheel forward and slide belt off.
10. Remove sprocket cover and five washers from sprocket.
11. Remove and discard sprocket. Discard five washers.
11 1
WARNING
Always wear proper eye protection and gloves when
working with compressed air. Compressed air may eject
debris with enough force to cause injury. Inadequate
safety precautions may result in death or serious injury.
12. Clean residual loctite from threads in wheel sprocket
towers with a suitable non-flammable solvent. Dry with
compressed air.
13. Remove three TORX bolts, washers and front sprocket
cover from right side of motorcycle. NOTE: It may be
necessary to compress suspension to gain access to
front sprocket cover TORX bolt.
14. Remove two TORX screws and washers from right side
of rear inner fender. Carefully bend rear inner fender
upwards and remove drive belt. Discard drive belt.
15. Position new drive belt over transmission drive sprocket.
16. Install rear inner fender with two TORX screws and
washers. See 2.23 FENDERS.
17. Install front sprocket cover with three TORX screws and
washers. See 2.22 SPROCKET COVER.
18. Position rear sprocket on rear wheel with mounting holes
aligned.
11 1
WARNING
Use only new P/N BA0511.2Z hardened washers between
sprocket cover and sprocket. Failure to use hardened
washers could cause sprocket to fail. Drive sprocket fail-
ure could lead to loss of control of vehicle which could
result in death or serious injury.
19. Place new hardened washers on sprocket and install
new sprocket cover over washers and sprocket.
20. Install sprocket and sprocket cover with five new
sprocket bolts. Tighten bolts to 28-31 ft-lbs (38-42 Nm).
SEAT.
WARNING
WARNING
WARNING
21. Place wheel centrally in the swingarm. Slide wheel far
enough forward to slip belt over sprocket and rest belt on
sprocket inboard of the teeth.
NOTE
Do not place belt on sprocket teeth at this time. Alignment of
parts will be difficult. Resting belt next to teeth allows slack for
easier alignment of wheel assembly.
22. Hold left side spacer in place and slide caliper and car-
rier over rotor.
23. Slide axle through washer, swing arm, carrier, left side
spacer and wheel assembly.
a. See Figure 1-20. Hold right side spacer in place.
b. Insert axle through right side spacer and swingarm.
c. Install flat washer, lockwasher and axle nut.
24. Place screwdriver or rod through axle hole and torque
rear axle nut to 48-52 ft-lbs (65.1-70.5 Nm).
25. Slide belt on sprocket teeth by rotating wheel to "walk"
belt onto teeth.
26. Lower motorcycle rear wheel.
27. Connect negative battery cable to battery. Tighten fas-
tener to 60-96 in-lbs (6.8-10.9 Nm).
28. Install seat. See 2.28 SEAT.
7747
Axle
Hole
Figure 1-19. Rear Wheel Mounting
7701
Washer
Spacer
Axle
Nut
(metric)
Sprocket
Cover
Figure 1-20. Rear Axle, Right Side
2002 Buell P3: Maintenance
Washer
Axle
Nut
(metric)
Lockwasher
Lockwasher
Axle
Sprocket
Bolts (5)
1-21