Buell 2002 P3 Service Manual

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2002 BUELL P3

SERVICE MANUAL

Part Number 99491-02Y

Section 1: Maintenance

Section 2: Chassis

Section 3: Engine

Section 4: Fuel System

Section 5: Starter

Section 6: Drive/Transmission

Section 7: Electrical

Appendix

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Page 1 2002 BUELL P3 SERVICE MANUAL Part Number 99491-02Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendix...
Page 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-43988 Camshaft Bushing Reamer Fixture. Part No. HD-33223-1 Cylinder Compression Gauge Use with Part No. HD-38871-2. Part No. HD-33413-A Carburetor Idle Adjustment Tool Part No. B-43991 Fork Seal/Bushing Driver Part No. HD-33416 Universal Driver Handle Part No. B-59000A Pro Level Oil Gauge Part No.
Page 5 HOME Part No. HD-33446A Cylinder Torque Plates Part No. HD-34723 Valve Guide Hone (8 mm) and Torque Plate Bolts Part No. HD-33446-86. Part No. HD-33813 Inductive Timing Light Part No. HD-34731 Shoulderless Valve Guide Installation Tool Part No. HD-34623B Piston Pin Part No.
Page 6 HOME Part No. HD-35381 Belt Tension Gauge Part No. HD-34751 Nylon Valve Guide Brush 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.
Page 7 HOME Bdhgkjsbkdv ' ksjjlkn lk CYLINDER LEAKDOWN TESTER knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno[bho Bdhgkjsbkdv ' ksjjlkn lk knsdl hlno hslnsln nlslns finbp pklhb knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno[bho knsdl hlno hslnsln nlslns finbp pffb Bdhgkjsbkdv Majjlkn Nolk odlbndpob npdb ndbno[bho...
Page 8 HOME Part No. HD-38515-A Clutch Spring Compressing Tool Part No. HD-39302 Steering Head Bearing and Part No. HD-38515-91 Forcing Screw. Race Installer 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.
Page 9 HOME Part No. HD-39621 Electrical Terminal Repair Kit Part No. HD-39823 Oil Filter Crusher, Large 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.
Page 10 HOME Part No. HD-39965 Deutsch Terminal Crimp Tool Part No. HD-41155 VHS Video Shelf 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.
Page 11 HOME Part No. HD-41405 Main Drive Gear Seal Installer Part No. HD-42310 Engine/Transmission Stand 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.
Page 12 HOME Made in USA PP-9606- 0001 Part No. HD-42376 Battery/Charging System Part No. HD-43984 Crankshaft Locking Tool Load Tester 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.
Page 13 HOME Part No. HD-44404 Timkin Bearing Remover. Use with Part No. HD-94800-26A Connecting Rod Bushing Part No. HD-44069. Reamers and Pilots 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.
Page 14 HOME Part No. HD-94812-87 Pinion Shaft Reamer Pilot. Part No. HD-95760-69A Bushing/Bearing Puller Tool Set Use with Part No. HD-94812-1. Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD- 95770-69) and 10 (HD-95771-69) are optional. Part No. HD-95017-61 Large External Retaining Part No.
Page 15 HOME Part No. HD-96295-65D Timing Mark View Plug. Part No. HD-96718-87 Pinion Bearing Outer Race Use with Part No. HD-33813. Lapping Kit 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.
Page 16 HOME Part No. HD-97087-65B Hose Clamp Pliers Part No. HD-97292-61 Two Claw Puller Part No. HD-97273-60 Camshaft Bushing Installer Part No. J-5586 Transmission Shaft Retaining Ring Pliers A-14 Appendix A: Tools...
Page 17 HOME A-15 Appendix A: Tools...
Page 18: Electrical Connectors
HOME ELECTRICAL CONNECTORS GENERAL NOTE Male ends of connectors are labeled “A” in text. The following table provides a description of the connectors Female ends of connectors are labeled “B” in text. found on your motorcycle. Connector numbers are listed in [brackets] in this manual. Table B-1.
Page 19: 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 20 HOME Raise locking bar by pushing up on bottom ﬂange. With a0267x7x the crimp tails facing upward and the rounded side of the contact barrel resting on the concave split level area of the crimp tool, insert contact (socket/pin) through middle hole of locking bar.
Page 21: Amp Multilock Electrical Connectors
HOME AMP MULTILOCK ELECTRICAL CONNECTORS REMOVING SOCKET/PIN a0269x7x TERMINALS 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 22 HOME INSTALLING SOCKET/PIN a0271x7x TERMINALS 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. ●...
Page 23 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 24 LT. LIGHT BATT ERY STATOR PARK 6A RATING LOC K 12A RATING 6A RATING ZADI KEY SWITC H 16 R/BK 18 O/W KEY SWITC H LOGI C Figure B-10. 2001 Buell Blast P3 Model - Main Harness Appendix B: Wiring...
Page 25 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. 2001 Buell Blast P3 Model - Starting Appendix B: Wiring...
Page 26 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. 2001 Buell Blast P3 Model - Charging Appendix B: Wiring...
Page 27 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. 2001 Buell Blast P3 Model - Horn and Instruments B-10 Appendix B: Wiring...
Page 28 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. 2001 Buell Blast P3 Model - Lighting Appendix B: Wiring B-11...
Page 29 FROM TN/GN START RELAY TN/Y TN/Y TN/W CL UTC H SWITC H TN/GN R/BK KEY SWITC H R/BK FUSE BLOC K R/BK1 (TOP VIEW) SYSTEM RELAY BATTERY Figure B-15. 2001 Buell Blast P3 Model - Ignition B-12 Appendix B: Wiring...
Page 30 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 31 WARNING meters, use the formulas given under the metric chart. For all The quality fasteners used on Buell motorcycles have other steel fasteners, use the values listed in one of the tables speciﬁc strength, ﬁnish and type requirements to per- below.
Page 32 HOME Appendix C: Metric Conversions...
Page 33: Table Of Contents
MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fluid Requirements .
Page 34: General
After a new motorcycle has been driven its ﬁrst 1000 miles and adjustable lifting beam or sling are needed to remove (1600 km) and every service interval thereafter, have a Buell some parts. The lengths of chains or cables from the hoist to dealer perform the service operations listed in Table 1-1.
Page 35: Repair And Replacement Procedures
Dis- card parts that are worn. Be sure tapered splines are clean, dry and free of burrs before putting them in place. Press mat- ing parts together tightly. 2002 Buell P3: Maintenance...
Page 36: Part Replacement
Do not replace parts individually; ratch- ● Never point an air tool at yourself or another person. ets should be rebuilt with the entire contents of service ● Protect bystanders with approved eye protection. kit. 2002 Buell P3: Maintenance...
Page 37: 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. 2002 Buell P3: Maintenance...
Page 38 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 2002 Buell P3: Maintenance...
Page 39: 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 40: Body Panel Care/Maintenance
The purpose of this topic is to provide special care and main- Rinse surface with water. tenance instructions required for the molded-in-color body panels that are standard on your Buell Blast P3 motorcycle. Wash with Harley Wash or Harley Sun Wash. Molded-in-color surfaces look like painted surfaces, but are Rinse surface thoroughly with water.
Page 41 HOME NOTES 2002 Buell P3: Maintenance...
Page 42: Battery
(black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm). Apply a light coat of petroleum jelly or corrosion retar- dant material to both battery terminals. Install seat. See 2.28 SEAT. 2002 Buell P3: Maintenance...
Page 43: Engine Lubrication System
Below 40˚F (4˚C) Excellent HD Multi-grade 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 2002 Buell P3: Maintenance...
Page 44 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. 2002 Buell P3: Maintenance 1-11...
Page 45: 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. 1-12 2002 Buell P3: Maintenance...
Page 46: Rear Brake Pedal
Tighten locknut. brake lever/pedal to return slowly to its released position. Repeat Steps 2-4 until all air bubbles are purged. NOTE Tighten bleeder valve (metric) to 3-5 ft-lbs (4.1-6.8 Nm). Brake pedal has no freeplay adjustment. 2002 Buell P3: Maintenance 1-13...
Page 47: Brakes Pads And Rotors
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. (0.45 mm) ● Rotational Movement: 0.02 in. (0.39 mm) 1-14 2002 Buell P3: Maintenance...
Page 48: Tires And Wheels
The wheel bearings are sealed units, no greasing or mainte- nance is required. Replace when worn. Excessive play or roughness indicates worn bearings that require replacement. Check wheel bearings: ● Whenever wheel is removed (tire change, fork oil change). 2002 Buell P3: Maintenance 1-15...
Page 49: Clutch
Figure 1-12. Install clutch inspection cover using three TORX screws with washers. Tighten in a crosswise pattern to 7-9 ft-lbs (9.5-12.2 Nm). 10. Check clutch cable freeplay. See Step 6 above. Figure 1-13. Adjusting Clutch Freeplay 1-16 2002 Buell P3: Maintenance...
Page 50: Transmission/Primary Fluid
Wipe any foreign material from the magnetic drain plug (3). Inspect O-ring for deterioration and replace as required. Reinstall drain plug with O-ring. Tighten drain plug to 14-30 ft-lbs (19.0-54 Nm). Remove seat. See 2.28 SEAT. 2002 Buell P3: Maintenance 1-17...
Page 51 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. 1-18 2002 Buell P3: Maintenance...
Page 52: Drive Belt And Rear Sprocket
Figure 1-17. Inspect each tooth of rear sprocket for: closely before condition 2 develops which will require belt replacement. Major tooth damage. Gouges caused by hard objects. 2002 Buell P3: Maintenance 1-19...
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 1-20 2002 Buell P3: Maintenance...
Page 54 19. Place new hardened washers on sprocket and install Bolts (5) Cover 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). Figure 1-20. Rear Axle, Right Side 2002 Buell P3: Maintenance 1-21...
Page 55: Primary Chain
At every 2,500 mile (4,000 km) interval thereafter. ADJUSTMENT Figure 1-21. Buell Blast Models are shipped with a spacer between the primary chain limiting screw and the Figure 1-22. Chain Limiting Screw-without Spacer locknut. The spacer is used to quickly get proper adjustment during production.
Page 56: Rear Shock Absorber
At every 10,000 mile (16,000 km) service interval. NOTE Rear shock absorber contains no user serviceable parts. Replace the shock absorber if it fails. Bolt Damper Bushing Damper Stopper Ring Spring Seat Spring Spring Seat Stopper Figure 1-24. Rear Shock Absorber Assembly 2002 Buell P3: Maintenance 1-23...
Page 57: Front Fork Oil
Figure 1-26. Remove slider tube cap. Figure 1-26. Slider Tube Cap 3769 Figure 1-27. Push down on the B-spring seat (O- ring included) and remove the stopper ring and spring seat. Figure 1-27. B-Spring Seat 1-24 2002 Buell P3: Maintenance...
Page 58 Push down on spring seat past groove to install stopper ring. Stopper ring will lock into groove when installed correctly. 12. See Figure 1-31. Install slider tube cap. 13. Install front forks. See 2.17 FRONT FORK. 2002 Buell P3: Maintenance 1-25...
Page 59: Steering Head Bearings
Nm) to seat bearing. Loosen cap nut and retighten to 28-32 ft-lbs (38-43 Nm). Recheck tension using spring scale. See Step 5. Tighten both lower triple clamp pinch screws to 22-29 ft- lbs (30-39 Nm). Figure 1-33. Fork Stem and Bracket Assembly 1-26 2002 Buell P3: Maintenance...
Page 60: Spark Plug
0.038-0.043 in. (0.97-1.09 mm). Apply LOCTITE ANTI-SEIZE to threads of spark plug. Install and tighten to 11-18 ft-lbs (14.9-24.4 Nm). Connect spark plug cable. Verify that cable is securely connected to ignition coil and spark plug. 2002 Buell P3: Maintenance 1-27...
Page 61: Air Cleaner
Do not use gasoline or solvents to clean the ﬁlter ele- 7757 ment. Volatile or ﬂammable cleaning agents may cause an intake system ﬁre, which could result in death or seri- ous injury. Figure 1-36. Remove Air Box From Bracket 1-28 2002 Buell P3: Maintenance...
Page 62 11. Lock ﬁve latches around perimeter of air box cover. 12. Install Phillips screw at bottom of air box cover (7 o’clock position) to secure cover to air box. Tighten screw to 4-6 in-lbs (0.5-0.7 Nm). 2002 Buell P3: Maintenance 1-29...
Page 63: Throttle Cables
Tighten adjuster lock (3) on idle control cable (2) adjuster (4). Recheck operation of throttle control (Step 7). Slide rubber boot (5) over each cable adjuster (4). Recheck engine slow idle speed; adjust if required. 10. Install air cleaner assembly. See 4.3 AIR CLEANER. 1-30 2002 Buell P3: Maintenance...
Page 64: 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 7-17). 10. See Figure 1-41. Tighten module plate screws to 15-30 in-lbs (1.7-3.4 Nm) 2002 Buell P3: Maintenance 1-31...
Page 65: Idle Speed Adjustment
Repeat steps 1, 2 and 3 until the tachometer has a read- ing of 1200 RPM. Turn the ignition switch to off position. Figure 1-43. Adjusting Idle Speed 1-32 2002 Buell P3: Maintenance...
Page 66: Fuel Supply Valve And Filter Strainer
Rotate handle of fuel supply valve to RES(ERVE) to start the ﬂow of fuel. See C of Figure 1-44. Once the fuel tank is completely drained, rotate han- dle of fuel supply valve to OFF. Remove spare hose from outlet ﬁtting. 2002 Buell P3: Maintenance 1-33...
Page 67 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. 1-34 2002 Buell P3: Maintenance...
Page 68: Starter Interlock And Electrical Switches 1.21
Clutch disengaged (lever pulled in - must be done whenever starting motorcycle). ● Transmission in Neutral ● Sidestand retracted If the motorcycle starts and operates without any of the three conditions being met, see 7.11 STARTER/IGNITION INTER- LOCK, for troubleshooting procedures. 2002 Buell P3: Maintenance 1-35...
Page 69: Critical Fastener Torque Values
Mufﬂer Fasteners (Front and Rear): ● 22-25 ft-lbs (30-34 Nm) Tie Bar (all): ● 30-33 ft-lbs (41-45 Nm) Engine Mount Fasteners: ● Front Isolator Mounting Bolt: 63-70 ft-lbs (86-95 Nm) ● Frame to rear isolator fastener: 30-33 ft-lbs (41-45 1-36 2002 Buell P3: Maintenance...
Page 70: Storage
If motorcycle is to be covered, use a material that will varnish in the carburetor. breathe, such as light canvas. Plastic materials that do This work should be performed by your local Buell dealer or not breathe promote the formation of condensation. other qualiﬁed technician following Service Manual proce- dures.
Page 71: Troubleshooting
Fuel tank ﬁller cap vent plugged, or carburetor fuel line Valve Train Noise closed off restricting fuel ﬂow. 10. Water or dirt in fuel system and carburetor. Hydraulic lifter not functioning properly. 11. Enrichener valve inoperative. Bent push rod. 1-38 2002 Buell P3: Maintenance...
Page 72: Electrical System
Engine ground wire loose or broken. Loose or broken wires in charging circuit. Stator not functioning. Rotor not functioning. Alternator Charge Rate Is Below Normal Regulator-rectiﬁer module not functioning. Stator not functioning. Rotor not functioning. Weak battery. 2002 Buell P3: Maintenance 1-39...
Page 73 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. 1-40 2002 Buell P3: Maintenance...
Page 74 CHASSIS Table Of Contents SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 76: Specifications
30 PSI 36 PSI Gasoline Dunlop 120/80 16 60s K330 (207 kPa) (248 kPa) Use a good quality unleaded gasoline which is 87 pump octane or higher (R+M)/2. Octane rating is usually found on the pump. 2002 Buell P3: Chassis...
Page 77 Page 2-64 Rear axle nut 48-52 ft-lbs 65-71 Nm Page 2-50 Rear brake caliper mounting screw, 18-22 ft-lbs 24-30 Nm Metric, Page 2-31 large Rear brake caliper mounting screw, 15-18 ft-lbs 20-24 Nm Metric, Page 2-31 small 2002 Buell P3: Chassis...
Page 78 243 (blue) to last few threads, Page 2-50 Switchgear housing screws, right side 12-17 in-lbs 1-2 Nm Metric, Page 2-34 Valve stem nut 42-44 in-lbs 4.7-5.0 Nm Page 2-17 Windscreen screws 9-11 in-lbs 1 Nm Page 2-59 2002 Buell P3: Chassis...
Page 79: 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 2002 Buell P3: Chassis...
Page 80: Vehicle Identification Number
VEHICLE IDENTIFICATION NUMBER GENERAL NOTE Always give the full 17-digit Vehicle Identiﬁcation Number when ordering parts or making inquiries about your Buell Figure 2-1. Each vehicle has a 17-digit serial or Vehicle motorcycle. Identification Number (V.I.N.) stamped on the steering head.
Page 81: 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. 2002 Buell P3: Chassis...
Page 82 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 83: Front Wheel
Never replace just one brake pad. Fail- Pinch Screw Axle Nut (metric) ure to install brake pads as a set could result in death or Spacer (and washer) serious injury. Figure 2-5. Front Wheel Mounting Inspect brake rotor and pads. 2002 Buell P3: Chassis...
Page 84 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 2002 Buell P3: Chassis...
Page 85 Tighten the front axle pinch screw to 13-16 ft-lbs (18- Verify that wheel and tire are true. See 2.8 CHECKING 22 Nm). CAST RIM RUNOUT. Install front brake caliper. See 2.11 FRONT BRAKE Balance tire. See 2.9 TIRES, Adjustment. CALIPER. 2-10 2002 Buell P3: Chassis...
Page 86: Rear Wheel
Lay wheel on clean work area with rotor side down. result in death or serious injury. Position sprocket on rim with holes in sprocket and rim aligned. 2002 Buell P3: Chassis 2-11...
Page 87: Nut (Metric)
Left Axle Spacer 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 Figure 2-9. Rear Wheel Assembly 2-12 2002 Buell P3: Chassis...
Page 88 Slide belt on sprocket teeth by rotating wheel to “walk” belt onto teeth. Figure 2-10. Rear Axle, Left Side Lower motorcycle rear wheel. 7701 Axle Axle Nut (metric) Lockwasher Washer Spacer Sprocket Bolts (5) Sprocket Cover Figure 2-11. Rear Axle, Right Side 2002 Buell P3: Chassis 2-13...
Page 89: Sealed Wheel Bearings
(1) and turn the nut (2) to remove bearing from wheel. Remove spacer from inside wheel hub. Repeat procedure for opposite side bearing. Discard all bearings upon removal. Forcing Screw Figure 2-14. Remove Bearing 2-14 2002 Buell P3: Chassis...
Page 90: Wheel Bearing
Parts 1-7 common to removal/installation. Pilot, 3/4 in. B-43993-6 Parts 8-9 used for removal only. Support Plate B-43993-1 Parts 10-13 used for installation only. Threaded Rod 280856 Figure 2-17. Wheel Bearing Remover/Installer (Part No. B-43933) 2002 Buell P3: Chassis 2-15...
Page 91: Checking Cast Rim Runout
MAXIMUM MAXIMUM WHEEL TYPE LATERAL RADIAL RUNOUT RUNOUT Wheel Truing and Balancing Stand (Part No. HD-99500-80) Cast 0.040 in. 0.030 in. (1.02 mm) (0.76 mm) Gauge Rod Figure 2-19. Checking Cast Rim Radial Runout 2-16 2002 Buell P3: Chassis...
Page 92: Tires
WARNING WARNING Dunlop front and rear tires for Buell motorcycles are not the same. They are not interchangeable. Use front tire ONLY for a front tire. DO NOT put a rear tire on the front of a vehicle.
Page 93 Check rim bead side runout. See 2.8 CHECKING CAST Gauge RUNOUT. Replace rims not meeting speciﬁcations. Install tire and check again for tire tread lateral runout. Figure 2-24. Checking Tire Radial Runout 2-18 2002 Buell P3: Chassis...
Page 94: Wheel Balancing
BONDER 420 to adhesive side of weight. Place weight on ﬂat surface of wheel rim. Press weight ﬁrmly in place and hold for ten seconds. Allow eight hours for adhesive to cure completely before using wheel. 2002 Buell P3: Chassis 2-19...
Page 95: Front Brake Master Cylinder
Remove two screws (1) (metric) and clamp (2) to detach master cylinder assembly from handlebar. Clamp Screws (2) (metric) Clamp Master Cylinder Cover Screws (2) Banjo Washers (2) Brake Line Banjo Bolt (metric) Figure 2-27. Front Master Cylinder 2-20 2002 Buell P3: Chassis...
Page 96 Inspect outlet port that mates with brake line ﬁtting. As a critical sealing surface, replace housing if any scratches, dents or other damage is noted. Inspect boot for cuts, tears or general deterioration. Replace as necessary. Boot Piston Snap Ring Figure 2-30. Snap Ring 2002 Buell P3: Chassis 2-21...
Page 97 Figure 2-33. Brake Fluid Level Figure 2-33. With the master cylinder in a level posi- tion, add D.O.T. 4 BRAKE FLUID. Bring ﬂuid level to within 0.125 in. (3.2 mm) of molded boss inside front master cylinder reservoir. 2-22 2002 Buell P3: Chassis...
Page 98 If brakes are not operating prop- erly, or braking efﬁciency is poor, testing at high speeds could result in death or serious injury. Screw, Lockwasher and Washer Hand Lever Tang Figure 2-35. Testing Hand Lever 2002 Buell P3: Chassis 2-23...
Page 99: Front Brake Caliper
(2) from their respective grooves in caliper. Banjo Bolt (metric) Mounting Screws (2) Discard seals. Banjo Washers (2) Bleeder Valve Check bleeder valve (metric). Remove and replace if Wireform damaged. Figure 2-36. Front Brake Caliper 2-24 2002 Buell P3: Chassis...
Page 100 Install two new seals in outer grooves of each piston bore. Install two new seals in inner grooves of each piston bore. Install pistons (3) in each piston bore. Install a new bleeder valve (metric) if necessary. Tighten to 3-5 ft-lbs (4-7 Nm). 2002 Buell P3: Chassis 2-25...
Page 101 WARNING Verify proper operation of the master cylinder relief port. A plugged or covered relief port can cause brake drag or lockup, which could result in loss of vehicle control and death or serious injury 2-26 2002 Buell P3: Chassis...
Page 102: Front Brake Line
Tighten master cylinder banjo bolt (1) (metric) to 16-20 Caliper Banjo Bolt (metric) ft-lbs (22-27 Nm). Banjo Washers (2) Install bleeder valve if removed. Reﬁll master cylinder and bleed brakes. Figure 2-41. Front Brake Line 2002 Buell P3: Chassis 2-27...
Page 103: Rear Brake Master Cylinder
Banjo Washers (2) Rubber Boot Brake Line 10. Locknut Master Cylinder 11. Clevis Screw (2) (metric) 12. Clevis Pin Piston Assembly 13. Remote Reservoir Push Rod 14. Spacer (2) Figure 2-43. Rear Master Cylinder Assembly 2-28 2002 Buell P3: Chassis...
Page 104 Add der (4) with two new banjo washers (2) and banjo bolt (1) D.O.T. 4 BRAKE FLUID if necessary. Be sure gasket (metric). Tighten to 16-20 ft-lbs (22-27 Nm). and cap on reservoir ﬁt securely. 2002 Buell P3: Chassis 2-29...
Page 105 Figure 2-45. Remote Reservoir 6506 Master Cylinder Body Snap Ring Rod Assembly Piston Assembly Figure 2-46. Master Cylinder Internals 2-30 2002 Buell P3: Chassis...
Page 106: Rear Brake Caliper
Adaptor Piston Figure 2-49. Removing Rear Brake Caliper Piston Brake Line Banjo Bolt (metric) Banjo Washers (2) Bleeder Valve (metric) Pin Plug and Pad Hanger (metric) Small Screw (metric) Figure 2-47. Rear Brake Caliper (Typical) 2002 Buell P3: Chassis 2-31...
Page 107 Place two new O-rings inside grooves of piston ing or bleeding system. To prevent death or serious bore. injury, Buell strongly recommends that all brake repairs be performed by a Buell dealer or other qualiﬁed techni- Install piston inside caliper body. cian. Figure 2-50.
Page 108 Distorted, glazed or contaminated brake pads. Replace pads. Brake pads drag on rotor – Cup in master cylinder not uncovering relief port. Inspect master cylinder. will not retract. Rear brake pedal linkage out of adjustment. Adjust linkage. 2002 Buell P3: Chassis 2-33...
Page 109: Rear Shock Absorber
Stopper Ring cle and death or serious injury. Spring Seat Spring 2.28 SEAT. Remove lifting straps and install seat. Spring Seat Stopper Figure 2-51. Rear Shock Absorber Assembly 2-34 2002 Buell P3: Chassis...
Page 110: Throttle Control
Attach housings with two screws, installing longer screw on bottom. Tighten to 12-17 in- lbs (1-2 Nm). Adjust cables. See 1.18 THROTTLE CABLES. 10. Install fuel tank. See 4.2 FUEL TANK COVER/FUEL TANK. 2002 Buell P3: Chassis 2-35...
Page 111 HOME NOTES 2-36 2002 Buell P3: Chassis...
Page 112: Front Fork
18. Fork Assembly (slider & tube, right & left) Damper Assembly 19. Slider Assembly (left & right) Lock Piece 20. Front Fork Bolt 10. Rebound Spring 21. Center Bolt 11. Slide Bushing 22. Reﬂector Figure 2-54. Front Fork Assembly 2002 Buell P3: Chassis 2-37...
Page 113: Front Fork Removal
Loosen the large pinch screws on both the upper and lower triple clamps. Lower Triple Clamp Figure 2-56. Pinch Screws Figure 2-57. Remove front fork. Repeat procedure for the other front fork. 3766 Figure 2-57. Front Fork Removal 2-38 2002 Buell P3: Chassis...
Page 114: Front Fork Disassembly
Figure 2-59. Remove slider tube cap. Figure 2-59. Slider Tube Cap 3769 Figure 2-60. Push down on the B-spring seat (O- ring included) and remove the stopper ring and spring seat. Figure 2-60. B-Spring Seat 2002 Buell P3: Chassis 2-39...
Page 115 8-10 times until the rod moves freely. Figure 2-62. Pumping Fork Oil Figure 2-63. Remove the center bolt (metric) from 3771 the bottom of the fork tube. Figure 2-63. Removing Center Bolt 2-40 2002 Buell P3: Chassis...
Page 116 Figure 2-65. Removing Dust Seal 10. See Figure 2-66. Pull the slider tube out of the slider 3773 assembly. Remove oil seal, back-up ring and guide bush- ing. Oil Seal Backup Ring Guide Bushing Figure 2-66. Removing Slider Tube 2002 Buell P3: Chassis 2-41...
Page 117 .69 in. (17.4 mm). Slider Tube Figure 2-69. Measure slide pipe runout. Replace pipe if runout exceeds the service wear limit of 0.008 in. (0.2 mm). Slide Bushing Figure 2-68. Slider tube Components a0001xSx Figure 2-69. Pipe Runout 2-42 2002 Buell P3: Chassis...
Page 118: Front Fork Assembly
Install slide bushing onto the slide pipe. Figure 2-70. Install Slide Bushing Figure 2-71. Install damper assembly and rebound 3794 spring into slider tube. Figure 2-71. Damper Assembly Figure 2-72. Install lock piece into damper 3791 Figure 2-72. Lock Piece 2002 Buell P3: Chassis 2-43...
Page 119 The outer tube can move freely up and down on the slide pipe. Always hold both the slide pipe and outer tube to prevent damage to bushings and seals. Figure 2-74. Slider Tube 3796 Figure 2-75. Install spring onto damper assembly. Figure 2-75. Install Rebound Spring 2-44 2002 Buell P3: Chassis...
Page 120 Figure 2-77. Install Guide Bushing 11. See Figure 2-78. Wrap the end of the slide pipe and the 3781 slide bushing channel with tape to avoid damaging the oil seal lip when installing. Figure 2-78. Slider Tube Protection 2002 Buell P3: Chassis 2-45...
Page 121 15. See Figure 2-81. Install retaining ring. Verify ring is under 3786 groove inside slider assembly. Retaining Ring Groove Figure 2-81. Install New Retaining Ring 16. See Figure 2-82. Install new dust seal onto slide pipe. 2-46 2002 Buell P3: Chassis...
Page 122 Figure 2-84. Push down on spring seat past groove to install stopper ring. Stopper ring will lock into groove when installed correctly. 3781 Figure 2-83. Remove Slider Tube Protection 3769 Figure 2-84. Compressing Spring Seat 2002 Buell P3: Chassis 2-47...
Page 123: Front Fork Installation
Figure 2-86. Installing Fork Tube 3777 Figure 2-87. Apply LOCTITE ANTI-SEIZE to the threads of triple clamp pinch screws. Anti-Seize Figure 2-87. Triple Clamp Pinch Screw Figure 2-88. Align and secure fork tubes. 2-48 2002 Buell P3: Chassis...
Page 124 Install front wheel. See 2.5 FRONT WHEEL. Clamp Install front brake caliper. See 2.11 FRONT BRAKE CALIPER. Align head lamp. See 7.17 HEADLAMP. Figure 2-88. Pinch Screws a0065aSx Headlamp Bracket Screws Figure 2-89. Tighten Head lamp Bracket 2002 Buell P3: Chassis 2-49...
Page 125: Fork Stem And Bracket Assembly
Insert lower triple clamp (6) through the steering head. 11. Connect battery negative cable. Install the upper bearing (1) with small end down and dust shield (3) onto fork stem. 12. Install seat. See 2.28 SEAT. 2-50 2002 Buell P3: Chassis...
Page 126 Raise front wheel off ﬂoor using a ﬂoor hoist and lifting straps. Turn front wheel to full right lock. Figure 2-91. Attach a spring scale into the hole in the front axle. Pull front wheel to center position. It 2002 Buell P3: Chassis 2-51...
Page 127: Swingarm
If brakes are not operating properly or braking efﬁciency is poor, testing at high speeds could result in death or serious injury. Install drive belt. Install rear fender, lower belt guard, and sprocket cover. 2-52 2002 Buell P3: Chassis...
Page 128: Exhaust System
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 2-93. Exhaust System Assembly 2002 Buell P3: Chassis 2-53...
Page 129: Muffler Removal
Install new exhaust port gasket (1). Position mufﬂer on motor. Hand tighten nuts (13). Slide mufﬂer over bushings on front mount. Hand thread bolt washer and nut to front mufﬂer support. Install rear mufﬂer strap(15). 2-54 2002 Buell P3: Chassis...
Page 130: Footpeg Support Bracket
Align footpeg mounting holes with foot- Oil Tank Drain Hose peg support bracket mounting holes. Insert dowel pin (and on rear peg, spacer) through Figure 2-95. Left Side Footpeg Support Bracket mounting holes. Install new cotter pin. 2002 Buell P3: Chassis 2-55...
Page 131: Sprocket Cover
Install master cylinder bolts and spacers. See 2.13 REAR BRAKE MASTER CYLINDER. Bolts Spacers Pedal Bolt Figure 2-96. Master Cylinder Mounting a0131x2x Nylon Washers (3) Screws (3) 30-36 in-lbs (3.4-4.1 Nm) Blue Loctite Figure 2-97. Sprocket Cover 2-56 2002 Buell P3: Chassis...
Page 132: Fenders
If seat is loose, it could shift Well Nut during vehicle operation, causing loss of control of vehi- cle and death or serious injury. Figure 2-100. Rear Fender Assembly 2002 Buell P3: Chassis 2-57...
Page 133: 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). Nylon Screws (2) Washers (2) 30-36 in-lbs (3-4 Nm) Figure 2-101. Lower Belt Guard 2-58 2002 Buell P3: Chassis...
Page 134: Tail Section And Rear Frame Assembly
Lock Washer 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 Figure 2-102. Tail Section 2002 Buell P3: Chassis 2-59...
Page 135 Slide rear frame assembly (10) into frame. during vehicle operation, causing loss of control of vehi- Install fasteners (11). cle and death or serious injury. Install brackets (12) and fasteners (13). Connect rear wire harness and mount on “T” stud. 2-60 2002 Buell P3: Chassis...
Page 136: Windscreen
Figure 2-104. Remove windscreen trim. Install two screws and nylon washers on each side. Tighten screws to 9-11 in-lbs (1 Nm). Remove windscreen mounting brackets. 3779 Figure 2-103. Remove Screws 3797 Figure 2-104. Windscreen Trim 2002 Buell P3: Chassis 2-61...
Page 137: Instrument Panel
Apply LOCTITE THREADLOCKER 243 (Blue) to threads Odometer Reset Switch Rubber Boot of mounting screws. Install dash with two mounting screws. Tighten screws to 30-36 in-lbs (3-4 Nm). Odometer Reset Switch Figure 2-105. Instrument Panel 2-62 2002 Buell P3: Chassis...
Page 138: Seat
If seat is loose, it could shift during operation of vehicle and result in death or serious injury. 3795 a0021aox Seat Latch Tongue Locating Tab Figure 2-109. Locking Seat Tongue Figure 2-106. Seat Latch 2002 Buell P3: Chassis 2-63...
Page 139: Side Stand
Install side stand using pivot pin and cotter pin. Connect spring to side stand and spring pin. Remove REAR WHEEL SUPPORT STAND (Part No. B- 41174). Inspect side stand and sidestand switch for proper oper- ation. 2-64 2002 Buell P3: Chassis...
Page 140: Handlebars
Clutch Lever Bolt Clutch Lever Handle Clutch Cable Switch 10. O-ring 11. Clamp 12. Left Handlebar Grip 13. Left Switch Assembly 14. Right switch Assembly 15. Throttle 16. Brake Lever Switch Figure 2-111. Handlebar Assembly 2002 Buell P3: Chassis 2-65...
Page 141: Front And Rear Isolators
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. 2-66 2002 Buell P3: Chassis...
Page 142 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. 2002 Buell P3: Chassis 2-67...
Page 143 HOME NOTES 2-68 2002 Buell P3: Chassis...
Page 144 HOME 2002 Buell P3: Chassis 2-69...
Page 145 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 148: Specifications
1.926 in. (min) 48.920 mm (min) Intake 1.577-1.683 in. 38-49 lbs 17-22 kg (closed) 1.112-1.218 in. 98-112 lbs 44-51 kg (open) Exhaust 1.577-1.683 in. 38-49 lbs 17-22 kg (closed) 1.158-1.264 in. 91-106 lbs 41-48 kg (open) 2002 Buell P3: Engine...
Page 149 0.05080 mm Side play between ﬂywheels 0.005-0.025 in. 0.127-0.635 mm 0.030 in. 0.762 mm Fit on crankpin (loose) 0.0004-0.0017 in. 0.0102-0.0432 mm 0.0027 in. 0.0686 mm Connecting rod race ID 41.2623-41.2750 1.6245-1.6250 in. 1.6270 in. 41.3258 mm 2002 Buell P3: Engine...
Page 150 31.7398 mm (min) Outer race diameter in 39.7408-39.7561 1.5646-1.5652 in. 1.5672 in. (max) 39.8069 mm (max) right crankcase Bearing running clearance 0.00305-0.02235 0.00012-0.00088 in. Fit in cover bushing 0.0023-0.0043 in. 0.0584-0.1092 mm 0.0050 in. 0.1270 mm (loose) 2002 Buell P3: Engine...
Page 151 24-26 ft-lbs 32-35 Nm Page 3-15 LOCTITE® thread locker 262 (red), Top rear tie bar 30-33 ft-lbs 41-45 Nm Page 3-21 LOCTITE® thread locker 262 (red), Upper front tie bar 30-33 ft-lbs 41-45 Nm Page 3-21 2002 Buell P3: Engine...
Page 152: Engine
Your motorcycle will run normally using this type of gas. ing a need for engine repair are often misleading, but gener- Buell recommends you use it when possible, as an aid to ally, if more than one symptom is present, possible causes cleaner air in our environment.
Page 153: Diagnosing Smoking Engine Or High Oil Consumption
Remove air cleaner and set carburetor throttle in wide open position. Remove timing inspection plug from crankcase. The piston, in cylinder being tested, must be at top dead center of compression stroke during test. 2002 Buell P3: Engine...
Page 154: Stripping Motorcycle For Engine Repair/Removal
Remove the two mounted cylinder head bolts from the front isolator/engine bracket marked “DO NOT REMOVE”. See note above. NOTES: ● For top end service proceed to step 11. ● For engine removal proceed to step 12. 2002 Buell P3: Engine...
Page 155 12. For engine removal, loosen and remove lower front tie bar from engine. 13. See Figure 3-4. Remove top rear tie bar at frame. Frame Locknut Snubber Bolt Spacer Front Isolator Standoff Figure 3-3. Front Isolator Mount 7627 Figure 3-4. Remove Top Rear Tie Bar 2002 Buell P3: Engine...
Page 156 Breather Hose Three-way Connector Figure 3-7. Crankcase Breather Hose 7631 Air cleaner bracket (left front) Air cleaner bracket (right rear) Air cleaner screw Auto enrichener plug Frame Figure 3-8. Auto Enrichener Plug Figure 3-5. Air Cleaner Assembly 2002 Buell P3: Engine...
Page 157 10. Spacer Figure 3-10. Footpeg Bracket Assembly 23. See Table 3-3. Disconnect the following electrical items: a0017x3x Screw Brake ﬂuid reservoir Screw Brake line bracket Brake line Screw Master cylinder Spacer Figure 3-9. Brake Line Assembly 3-10 2002 Buell P3: Engine...
Page 158 Attach straps to frame and hoist. Raise hoist until straps tighten. 25. Remove rear shock. 2.15 REAR SHOCK ABSORBER. 26. See Figure 3-12. Loosen nut on hose routing clamp. Figure 3-11. Hoisting Bike 7718 Figure 3-12. Loosen Clamp 2002 Buell P3: Engine 3-11...
Page 159 Figure 3-14. Removing Rear Motor Mount Bolts 29. Remove chassis from engine by performing the steps 7651 below. Lower chassis. Disconnect hoist from chassis. Lower lift. Figure 3-15. Lift chassis and roll away from engine. Figure 3-15. Move Chassis From Engine 3-12 2002 Buell P3: Engine...
Page 160 Remove air cleaner box bracket. 7652 Figure 3-16. Bracket 31. See Figure 3-17. Remove rear engine mount. 7653 Figure 3-17. Rear Engine Mount 32. See Figure 3-18. Loosen swingarm pinch bolt. 7654 Figure 3-18. Pinch Bolt 2002 Buell P3: Engine 3-13...
Page 161 Remove swingarm pivot shaft and rear wheel as an assembly. See 2.19 SWINGARM. 7655 Figure 3-19. Swingarm Pivot Shaft 34. See Figure 3-20. Remove side stand and bracket 7656 assembly. See 2.29 SIDE STAND Figure 3-20. Side Stand Bracket 3-14 2002 Buell P3: Engine...
Page 162: Engine Installation
Figure 3-22. Swingarm Pivot Shaft Figure 3-23. Install swingarm pinch bolt. 7654 ® Apply several drops of LOCTITE THREAD- LOCKER 243 (blue) to last few threads. Tighten to17-19 ft-lbs (23-26 Nm). Figure 3-23. Pinch Bolt 2002 Buell P3: Engine 3-15...
Page 163 Attach straps to frame and hoist. Raise hoist until straps tighten. Place jack under the motor. Use jack to raise motor. Move jack backward. Figure 3-25. Bracket 7651 Figure 3-26. Move Chassis to Engine 3-16 2002 Buell P3: Engine...
Page 164 11. See Figure 3-29. Connect feed, return, transmission and crankcase vent lines. Figure 3-27. Hoisting Bike 7623 Figure 3-28. Installing Rear Motor Mount Bolts 7634 Oil return Transmission vent Crankcase vent Feed Figure 3-29. Connect Lines 2002 Buell P3: Engine 3-17...
Page 165 Located under seat (left side). Starter solenoid wire Disconnect at starter. [128] Spark plug wire Located on spark plug. Battery—positive wire Disconnect at main circuit breaker. Rear brake light switch Located under frame by shock absorber. [121] 3-18 2002 Buell P3: Engine...
Page 166 Brake Line Bracket Screw Brake Line Master Cylinder Spacer Figure 3-32. Brake Line Assembly a0016x3x Frame Locknut Washer Spacer Footrest Support Bracket Clevis Pin Footpeg Cotter Pin Index Plate 10. Spacer Figure 3-33. Footpeg Bracket Assembly 2002 Buell P3: Engine 3-19...
Page 167 Air Cleaner Bracket (left front) Frame Air Cleaner Bracket (right rear) Figure 3-34. Auto Enrichener Plug Air Cleaner Screw Figure 3-36. Air Cleaner Assembly 7649 7648 Breather Hose Three-way Connector Figure 3-35. Crankcase Breather Hose Figure 3-37. Hose Clamp 3-20 2002 Buell P3: Engine...
Page 168 Tighten bolts to 60 ft-lbs (27 Nm) initially and then Figure 3-38. Install Top Rear Tie Bar loosen each bolt one full turn. Tighten bolts again to 60 ft-lbs (27 Nm). 7628 Figure 3-39. Install Front Tie Bar 7646 Figure 3-40. Cylinder Head Bolt 2002 Buell P3: Engine 3-21...
Page 169 Figure 3-42. Install Crankcase Breather Hose 36. Connect both battery cables, positive cable ﬁrst. See 7.16 BATTERY. 37. Install seat. See 2.28 SEAT. 3-22 2002 Buell P3: Engine...
Page 170: Cylinder Head
19. Push Rod (exhaust) 20. Anti-Rotation Screw (2) 21. Push Rod cover 22. Washer (4) 23. Bolt (2) 24. Rocker Arm (intake) 25. Gasket (lower) 26. Bolt (2) 27. Gasket (inner) Figure 3-43. Rocker Arm Cover 2002 Buell P3: Engine 3-23...
Page 171 Mark valve to ensure that it will be reassembled in the same head. Remove valve, valve stem seal and lower collar. Figure 3-46. Valve Spring Compressor (Part No. HD-34736B) Repeat the above procedure for the other valve. 3-24 2002 Buell P3: Engine...
Page 172 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 3-47. Cylinder Head, Cylinder and Piston Assembly 2002 Buell P3: Engine 3-25...
Page 173 Measure bore of lower rocker cover. Figure 3-51. Measure rocker arm bushing inner diameter. Figure 3-49. Measuring Rocker Arm Shaft Diameter (Rocker Arm Bushing Position) 6607 Figure 3-50. Measuring Rocker Arm Shaft Bore Diameter in Lower Rocker Cover 3-26 2002 Buell P3: Engine...
Page 174 Check head gasket surface on head for ﬂatness. Machine or replace any head which exceeds SERVICE WEAR LIMIT of 0.006 in. (0.152 mm). Figure 3-52. Checking Spring Free Length 6609 Figure 3-53. Checking Gasket Surface 2002 Buell P3: Engine 3-27...
Page 175 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. 9/16 in. -18 tap Figure 3-54. Removing Rocker Arm Bushing 3-28 2002 Buell P3: Engine...
Page 176 Lubricate hone with honing oil. Driving hone with an electric drill, work for a crosshatch pattern with an angle of approximately 60°. Figure 3-56. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH) (Part No. HD-34751) and hot soapy water. 2002 Buell P3: Engine 3-29...
Page 177 (51.587 mm), replace valve seat or cylinder head. To achieve a smooth even ﬁnish, place a piece of 280 grit emery paper under the cutter head and rotate cutter. If valve stem protrusion is acceptable, valves and seats are ready for lapping. 3-30 2002 Buell P3: Engine...
Page 178 If inspection shows an unbroken lapped ﬁnish of uni- form width around both valve and seat, valve is well seated. If lapped ﬁnish is not complete, further lapping (or grinding and lapping) is necessary. Cylinder Head Holding Fixture (HD-39786) Figure 3-60. Lapping Valves 2002 Buell P3: Engine 3-31...
Page 179 10. Insert valve keepers into upper collar, making sure they engage groove in valve stem. The keeper gaps should be equal. 11. Release and remove VALVE SPRING COMPRESSOR. Sleeve 12. Repeat Steps 4-11 for the remaining valve. Figure 3-62. Valve Guide Seal Protector Sleeve 3-32 2002 Buell P3: Engine...
Page 180 Turn all bolts an additional 85 -95 . 12. See 3.15 HYDRAULIC LIFTERS. Install hydraulic lifters and push rod cover. 13. See Figure 3-64. Table 3-7.Identify push rod color coding, length and respective push rod positions in 2002 Buell P3: Engine 3-33...
Page 181 Screw with 135-155 in-lbs 1/4-20 X 1-1/2 washer (14) (15-18 Nm) Figure 3-65. Rocker Arm Cover Gaskets Bolt with 11-13 ft-lbs 1/4-20 X 1-1/4 washer (15) (15-18 Nm) 6616 Figure 3-66. Lower Rocker Box Fasteners 3-34 2002 Buell P3: Engine...
Page 182: Cylinder And Piston
Insert an awl in the recessed area below the piston pin bore and pry out the piston pin retaining rings. To prevent the ring from ﬂying out, place your thumb over the retain- ing ring. 2002 Buell P3: Engine 3-35...
Page 183 Check connecting rod for up and down play in lower bearings. When up and down play is detected, lower bearing should be reﬁtted. This requires removing and disassembling engine crankcase. a0099x3x V-groove Figure 3-68. Piston Pin and Piston Identiﬁcation 3-36 2002 Buell P3: Engine...
Page 184 Standard Bore 3.5008 88.9203 0.005 in. OS bore 3.5050 89.0270 (0.127 mm) 0.010 in. OS bore 3.5100 89.1540 (0.254 mm) 0.020 in. OS bore 3.5200 89.4080 (0.508 mm) 0.030 in. OS bore 3.5300 89.6620 (0.762 mm) 2002 Buell P3: Engine 3-37...
Page 185: Boring And Honing Cylinder
0.030 in. OS bore (0.762 mm) 3.527 in. 89.586 mm SERVICE WEAR LIMITS for end gap dimensions. Do *All bore sizes + 0.0002 in. (0.0051 mm) not ﬁle rings to obtain proper gap. 2783a Figure 3-72. Measuring Ring End Gap 3-38 2002 Buell P3: Engine...
Page 186 Position ring end gaps at arrows– rect, replace the rings, the piston or both. minimum of 90° apart FRONT Piston REAR Figure 3-74. Ring End Gap Position 6614 Figure 3-75. Measuring Ring Clearance in Groove 2002 Buell P3: Engine 3-39...
Page 187 Installing bent connecting rods will damage cylinder and Bolt piston beyond repair. Body Driver Nice Bearing Washer Figure 3-77. Piston Pin Bushing Tool Assembly for Bushing Removal 3-40 2002 Buell P3: Engine...
Page 188 Piston Pin Retaining Ring Installer (Part No. HD- 34623B) Figure 3-79. Installing Piston Retaining Rings a0102xSx Figure 3-80. Installing Retaining Ring Figure 3-81. Turn engine until piston is resting on top of PISTON SUPPORT PLATE (Part No. HD-42322) top dead center. 2002 Buell P3: Engine 3-41...
Page 189 3.5 CYLINDER HEAD. 14. Install assembled engine. See 3.4 ENGINE INSTALLA- TION. Piston Support Plate (Part No. HD-42322) Figure 3-81. Piston Support Plate 7657 Piston Ring Compressor (Part No. HD-96333- 51C) Figure 3-82. Compressing Piston Rings 3-42 2002 Buell P3: Engine...
Page 190: Lubrication System
The colder the weather, the shorter the recommended tion on checking oil level and changing oil and ﬁlter. oil change interval. A vehicle used only for short runs in cold weather must have the engine oil drained frequently. 2002 Buell P3: Engine 3-43...
Page 191: Oil Hose Routing
Steel line connection Feed Hose Figure 3-85. Oil Pump Connections Drain Hose Vent Hose Return Hose a0026x3x T-ﬁtting Figure 3-83. Oil Reservoir Hose Assembly Vent Hose Clamp Elbow Fitting Gearcase Cover Figure 3-86. Vent Hose Connection 3-44 2002 Buell P3: Engine...
Page 192: Oil Reservoir
A rubberized clamp secure the hoses in place. 3/8 inch Clamp Feed Hose Drain Hose 1/4 inch Clamp Vent Hose Return Hose T-ﬁtting Dipstick Figure 3-87. Oil Reservoir (Frame Backbone) 2002 Buell P3: Engine 3-45...
Page 193: 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). 3-46 2002 Buell P3: Engine...
Page 194: Crankcase Breathing System
(located by the oil Crankcase Breather Hose tank drain hose). The crankcase breather drain hose should Carburetor Venturi be drained at each oil change. Figure 3-89. Crankcase Breathing System, 2002 Buell P3: Engine 3-47...
Page 195: 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. 3-48 2002 Buell P3: Engine...
Page 196: 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 3-90. Oil Pump 2002 Buell P3: Engine 3-49...
Page 197 Measure thickness of feed gerotors with a microme- ter. Replace gerotors as a set if they are not the same thickness. Figure 3-93. Check gear shaft teeth for damage or wear. Replace if necessary. 3-50 2002 Buell P3: Engine...
Page 198 14. See 1.5 ENGINE LUBRICATION SYSTEM. Check Gerotor Separator Plate engine oil level. Add oil to correct level if needed. Slot on Separator Plate Tab on Oil Pump Body O-ring Figure 3-93. Separator Plate Slots 2002 Buell P3: Engine 3-51...
Page 199: Oil Filter Mount
Push threaded end of ﬁlter adapter (with LOCTITE) against check ball to compress spring. Screw adapter into threaded hole. Tighten to 8-12 ft- lbs (11-16 Nm). Install a new ﬁlter and ﬁll oil reservoir with proper oil. See 1.5 ENGINE LUBRICATION SYSTEM. 3-52 2002 Buell P3: Engine...
Page 200: Hydraulic Lifters
Inspect valve lifters for excessive clearance in guide. Accurately measure lifter bore inner diameter with a gauge. Clearance should be within 0.0008-0.0020 in. (0.0203-0.0508 mm). 2002 Buell P3: Engine 3-53...
Page 201 Push Rod Cover Screws (4) Push Rod Cover Push Rod Cover gasket Hydraulic Lifter (tappet) Anti- Rotation Screw Figure 3-96. Valve Lifter Service a0093x3x Base Circle (lowest position) Cam Lobe (maximum lift) Figure 3-97. Base Circle 3-54 2002 Buell P3: Engine...
Page 202: Gearcase Cover And Cam Gears
Cam Gear Shaft Outer Bushing 10. Key 11. Camshaft Cover Gasket 12. Gear Cover 13. Seal 14. Sems Screw 15. Oil vent hose ﬁtting 16. Clamp 17. Vent Hose 18. Outer Bushing Figure 3-98. Gearcase Cover & Cam Assembly 2002 Buell P3: Engine 3-55...
Page 203 Use GAUGE PIN SET (Part No. HD-38361) when Prior to changing any cam gears, check gear shaft ﬁt within measuring pinion and cam gear sizes. corresponding bushings. Worn bushings can cause exces- sive backlash. 3-56 2002 Buell P3: Engine...
Page 204 Table 3-12. 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) 2002 Buell P3: Engine 3-57...
Page 205 Bushing Reaming. After you install a new bushing in gearcase cover, line-ream the bushing to correct size. Gearcase Camshaft Bushing Installer (Part No. HD-97273-60 Universal Driver Handle (Part No. HD-33416) Figure 3-104. Arbor Press 3-58 2002 Buell P3: Engine...
Page 206 ﬁrst. ● After reaming any bushing, check shaft ﬁt in the bushing. It may be necessary to make a second pass with reamer to attain proper ﬁt. 2002 Buell P3: Engine 3-59...
Page 207 INTAKE CAM GEAR BUSHING IN Part No. HD-94812-87 as pilots for the reamer, to establish GEARCASE COVER correct clearance and to ensure proper alignment. If crank- 3-60 2002 Buell P3: Engine...
Page 208 Blow out all oil passages using compressed air. Pilot (Part No. HD-94812-87) Reamer (Part No. HD-94812-1) RIght Crankcase Gearcase Pinion Bushing Figure 3-109. Line Reaming Pinion Shaft Bushing 2002 Buell P3: Engine 3-61...
Page 209 7686 gear is installed. Figure 3-98. Install a new seal and new dry gear- cover gasket on crankcase. Figure 3-111. Crankshaft Locking Tool (HD-43984) 3-62 2002 Buell P3: Engine...
Page 210 Install cam position sensor and rotor in gearcase cover. Torque Sequence 7.8 IGNITION MODULE/ CAM POSITION SENSOR. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). 7683 Figure 3-113. Checking Cam Gear End Play 2002 Buell P3: Engine 3-63...
Page 211: 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 3-14. NOTE Use a thinner shim for less end play; use a thicker shim for more end play. 3-64 2002 Buell P3: Engine...
Page 212 Hex Socket Head Screw – 5/16-18 X 2-1/2 in. long (9) Rear Isolator 10. Screw (4) 11. Washer (4) Figure 3-115. Crankcase Hardware The next step requires using a press. Wear eye protec- tion and make certain set-up is stable. The pressure 2002 Buell P3: Engine 3-65...
Page 213 10. Gearshaft bearing will remain on ﬂywheel pinion shaft. 11. See Figure 3-118. Place ﬂywheel assembly in FLY- Remove retaining ring, and bearing may be slipped off WHEEL SUPPORT FIXTURE (Part No. HD-44385). Pull pinion shaft. sprocket shaft bearing with SPROCKET SHAFT INNER 3-66 2002 Buell P3: Engine...
Page 214 Figure 3-118. Removing Sprocket Shaft Roller Bearing Bearing Race Remover/Installer (Part no. HD- 34902B End Cap (Part No. HD-34902-7) Wedge Attachment for Claw Puller (Part No. HD- 95637-46A) Figure 3-120. Pulling Pinion Shaft Inner Race 2002 Buell P3: Engine 3-67...
Page 215 ROLLER OD (A) IDENTIFICATION* * Paint dot on end of spline Largest SERVICE WEAR LIMIT: 1.2492 in. (31.7297 mm) Blue White (Grey) Smallest Green Figure 3-121. Factory Inner Race Sizes * Package color Figure 3-123. Bearing Identiﬁcation 3-68 2002 Buell P3: Engine...
Page 216 ID measurement is 1.5651 in. correct inner race location is automatically established. (39.754 mm). This requires an inner race OD range Roundness: within 0.0002 in. (0.0051 mm) of 1.2496-1.2504 in. (31.740 - 31.760 mm). 2002 Buell P3: Engine 3-69...
Page 217 1.2502 1.2504 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 31.765 31.796 31.791 31.755 31.760 31.770 31.755 31.780 31.786 FACTORY COLOR CODE Green White 3-70 2002 Buell P3: Engine...
Page 218 Check connecting rod side play with a thickness gauge as shown. If side play measurement is greater than service wear limit listed below, replace ﬂywheel/connecting rod assembly. ● 0.030 in. (0.762 mm) Figure 3-127. Checking Connecting Rod Side Play 2002 Buell P3: Engine 3-71...
Page 219 Move snap ring if not properly centered. Loosen allen head screws and remove claws from snap ring a0096x3x HD-44069 Retaining Ring Remover/Installer Figure 3-128. Snap Ring Installation 3-72 2002 Buell P3: Engine...
Page 220 Slide sleeve over pilot until sleeve contacts inner bearing race. Install Nice bearing, washer and han- Figure 3-130. Right Outer Race Bearing Installation dle on top of sleeve. Rotate handle clockwise until bearing contacts ﬂy- wheel shoulder. Remove tool from sprocket shaft. 2002 Buell P3: Engine 3-73...
Page 221 SHAFT SEAL/SPACER INSTALLER (Part No. HD- 42774) onto sprocket shaft. Follow procedure in 7666 Step 8. Rotate handle clockwise until the spacer makes contact with the bearing. Remove tool from sprocket shaft. Figure 3-132. Installing Flywheel Spacer and Outer Bearing 3-74 2002 Buell P3: Engine...
Page 222 1.10 TRANSMISSION/PRIMARY FLUID. Be sure to reﬁll Shoulder on Cylinder Stud transmission to proper level with fresh lubricant. Air Gun 24. See 3.4 ENGINE INSTALLATION and perform the appli- Figure 3-135. Cylinder Studs cable steps. 2002 Buell P3: Engine 3-75...
Page 223 HOME NOTES 3-76 2002 Buell P3: Engine...
Page 224 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Tank Cover/Fuel Tank .
Page 226: Specifications
2-3 Nm Page 4-24 Triangular bracket to air box 3-5 ft-lbs 4-7 Nm Page 4-13 Vent tube ﬁtting 40-60 in-lbs 5-7 Nm Page 4-10 Ventrui ring to carburetor ﬂange 18-22 in-lbs 1.5-1.8 Nm Page 4-13 2002 Buell P3: Fuel System...
Page 227 Worn or damaged needle or needle jet. Replace assembly. Vacuum piston malfunction. See Table 4-2. Plugged jets or passages. Clean and clear as required. 10. Fuel level too low. 10. Adjust ﬂoat tab for correct fuel level. 2002 Buell P3: Fuel System...
Page 228 Worn or damaged needle or needle jet. Replace assembly. Vacuum piston assembly malfunction. See Table 4-2. Loose or plugged main jets or passages. Clean, clear and correct as required. 10. Improper fuel level. 10. Adjust ﬂoat level. 2002 Buell P3: Fuel System...
Page 229 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. 2002 Buell P3: Fuel System...
Page 230: Fuel Tank Cover
12. Moving to front of vehicle, pry rubber stops from weld studs on each side of frame backbone. See A and B of Figure 4-3. 13. Raise rear of fuel tank and slide assembly rearward to remove from frame. 2002 Buell P3: Fuel System...
Page 231: Fuel Cap
Rotate the locking tab 1/4 turn in a counter-clockwise Place fuel ﬁller cap into tank with the depression at the direction. front. Pull locking tab to remove fuel ﬁller cap from tank. Rotate the locking tab 1/4 turn in a clockwise direction. 2002 Buell P3: Fuel System...
Page 232 Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal. Rotate handle of fuel supply valve to RES(ERVE) to Drain fuel tank as follows: start the ﬂow of fuel. See C of Figure 4-5. 2002 Buell P3: Fuel System...
Page 233 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. 2002 Buell P3: Fuel System...
Page 234 Keeping ﬁngers at bottom of rollover valve, push on threaded end to remove from holes in fuel cap ﬂange and boot. See A of Figure 4-8. Remove fuel cap ﬂange and boot from fuel tank. 2002 Buell P3: Fuel System...
Page 235 Push down on rear of seat until spring-loaded latch fully engages groove of seat pin. 12. Verify that handle of fuel supply valve is in the OFF posi- tion and ﬁll the fuel tank. 4-10 2002 Buell P3: Fuel System...
Page 236: Tank Cover/Fuel Tank
Filter Strainer Wear Hose 1/4” I.D. x 1/2” O.D. Bracket Band Main NOTE Clamp Fuel Valve Hose is sold in bulk length only. Cut to required size. Screw (2) Figure 4-9. Fuel Tank Assembly 2002 Buell P3: Fuel System 4-11...
Page 237: Air Cleaner
Wash the ﬁlter element (and hose connections) in warm, soapy water. To remove soot and carbon, soak element for 30 minutes in warm water with mild detergent. Figure 4-11. Remove Air Box From Bracket 4-12 2002 Buell P3: Fuel System...
Page 238 11. Lock ﬁve latches around perimeter of air box cover. 12. Install Phillips screw at bottom of air box cover (7 o’clock position) to secure cover to air box. Tighten screw to 4-6 in-lbs (0.5-0.7 Nm). 2002 Buell P3: Fuel System 4-13...
Page 239 (Right Side) Rivet Screw Cover Seal Filter Air Box Cover a0181x4x NOTE Hose not identiﬁed as preformed is sold in bulk length only. Cut to required size. Figure 4-14. Air Cleaner Assembly (Non-California Models) 4-14 2002 Buell P3: Fuel System...
Page 240: Carburetor
Release idle and throttle cables from guides in throttle cable bracket and remove carburetor from vehicle. 10. Keeping carburetor upright, move to bench area. Without tilting carburetor or turning upside down, remove four 2002 Buell P3: Fuel System 4-15...
Page 241 Remove three remaining top screws to release carbure- tor top from body. Remove vacuum piston spring. Carefully raise dia- phragm to remove vacuum piston assembly. Remove spring seat and jet needle from vacuum piston bore. See Figure 4-16. 4-16 2002 Buell P3: Fuel System...
Page 242 Insert thin bladed ﬂat tip screwdriver into slow jet bore, and using slot at top of slow jet, unthread to remove. See Figure 4-17. and lower frame of Figure 4-18. Slow Jet Main Jet Fuel Valve Bore 7763 Figure 4-17. Carburetor Housing 2002 Buell P3: Fuel System 4-17...
Page 243 Examine tip of jet needle for grooves or scratches. bowl vent to blow carburetor cleaner out of holes in Needle should be completely straight, while surface ﬂoat bowl chamber. condition at taper should be smooth and even. Replace needle if necessary. 4-18 2002 Buell P3: Fuel System...
Page 244 To prevent bending bracket or Replace parts if damaged. 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...
Page 245 Install ﬂoat and check ﬂoat level again. Repeat pro- cedure as necessary until ﬂoat level is within speciﬁ- cation. Install new O-ring into groove of ﬂoat bowl, if removed. Be sure to thoroughly clean groove before O-ring instal- lation. 4-20 2002 Buell P3: Fuel System...
Page 246 Clamp Needle Fitting w/ Lockwasher Float Needle Jet Holder Float Bowl Main O-Ring Screw (4) Float Bowl Assembly NOTE Hose is sold in bulk length only. Cut to required size. Figure 4-21. Carburetor Assembly 2002 Buell P3: Fuel System 4-21...
Page 247: Auto-Enrichener
Remove pin terminals from chambers 1 and 2. NOTE For instructions on properly removing wire terminals, see Appendix B. 11. Remove Phillips screw (with lockwasher) to release stay plate on auto-enrichener from carburetor housing. Pull enrichener from carburetor bore. 4-22 2002 Buell P3: Fuel System...
Page 248: Hot Start
During some hot (warm) starts, the wax element may have cooled quicker than the engine, which can result in a fast idle period of short duration. When the wax element has cooled sufﬁciently, the silicone gradually contracts to pull the plunger in. At the end of its return Figure 4-23. Auto-Enrichener 2002 Buell P3: Fuel System 4-23...
Page 249 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. 4-24 2002 Buell P3: Fuel System...
Page 250: Throttle Position Sensor
SECTION 7, ELECTRICAL, DEUTSCH ELECTRICAL CON- NECTORS. 11. Using special TORX bit (Snap-on® TTXR20E), remove two tamper-resistant T20 TORX screws to release throt- tle position sensor from carburetor. Pull sensor from car- buretor bore. 2002 Buell P3: Fuel System 4-25...
Page 251 If the voltage reading is erratic or the volt- eter (Snap-on® ONO-SE-1100) to pick up the signal off the age reading at WOT exceeds 3.7V see Figure 7-10. for diagnostic testing. spark plug cable. 4-26 2002 Buell P3: Fuel System...
Page 252: Evaporative Emissions Control System
● Crankcase vapors passing through the PCV valve follow Buell motorcycles sold in the state of California are equipped the fuel vapors to the charcoal canister via a 3-way ﬁtting with an evaporative (EVAP) emissions control system. In con- plumbed into the PCV outlet hose.
Page 253 1/2” I.D. x 2” Long Not Sold in Bulk Length NOTE Unless indicated otherwise, hose Charcoal is sold in bulk length only. Cut to Canister required size. Tubing 5/32” I.D. Figure 4-27. Charcoal Canister Assembly 4-28 2002 Buell P3: Fuel System...
Page 254 ﬁtting at the front of the fuel cap ﬂange, runs down- barb is connected to a short hose that jumps to a second 3- ward on the left side of the fuel tank and turns rearward pass- 2002 Buell P3: Fuel System 4-29...
Page 255 (Non-California Models) Charcoal Canister Loop Oil Drain/Return Transmission Fitting/Hose Vent Hose Cable Strap Breather Hose Charcoal Canister Hose Breather Passenger Oil Drain Foot Peg Drain Hose Hose Support Figure 4-29. Hose Routing (Left Side View) 4-30 2002 Buell P3: Fuel System...
Page 256 HOME 2002 Buell P3: Fuel System 4-31...
Page 257 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 260: Specifications
8.1 ft-lbs (11.0 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Battery terminal bolts 60-96 in-lbs 7-11 Nm Page 5-18 Starter battery positive cable nut 80-100 in-lbs 9-11Nm Metric, Page 5-18 Starter mounting bolts 13-20 ft-lbs 18-27 Nm Page 5-18 2002 Buell P3: Electric Starter...
Page 261: 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). 2002 Buell P3: Electric Starter...
Page 262 Solenoid Plunger Main Solenoid Contacts Battery 10. Pull-in Winding 11. Hold-in Winding 12. Overrunning Clutch 13. Clutch Ring Gear Starting circuit-see wiring diagram Starter during cranking Starting circuit see wiring diagram Figure 5-1. Starter Operation 2002 Buell P3: Electric Starter...
Page 263 Excessively worn teeth. Replace ring gear. Solenoid Return spring worn. Replace solenoid. Coil layer shorted. Contact plate melted and stuck. Starting Switch or Unopened contacts. Replace starting switch or starter relay. Starter Relay. Poor returning. 2002 Buell P3: Electric Starter...
Page 264: Starter Diagnostics
Battery Voltage Present? Correct Relay 5832 5831 a0192x5x Ground. 5828 Replace Right Repair Wiring to Motor terminal Battery terminal Handlebar Starter Button. Switch gear. 5831 Continued on 5816 Next Page Figure 5-2. Starting System Diagnosis, Part 1 2002 Buell P3: Electric Starter...
Page 265 5.6 STARTER SYSTEM Primary Drive. for Opens, Shorts TESTING. or Grounds. Replace or Repair FREE RUNNING CURRENT DRAW TEST under STARTER. Starter Motor. DIAGNOSTICS in 7.11 STARTER/IGNITION INTERLOCK. 5817 Figure 5-3. Starting System Diagnosis, Part 2 2002 Buell P3: Electric Starter...
Page 266: 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. 2002 Buell P3: Electric Starter...
Page 267: Diagnostics/Troubleshooting
12 volts, displaying all the voltage dropped, and the caused by the powdered paint will cause a voltage entire difference in potential displayed on the meter. drop or potential difference in the ground circuit. 2002 Buell P3: Electric Starter...
Page 269: Starter System Testing
Typical starter current draw will range between 80- 130 amperes. If starter current draw exceeds 130 amperes, then the problem may be in the starter or starter drive. Remove starter for further tests. See STARTER. 5-10 2002 Buell P3: Electric Starter...
Page 270: Starter
Remove nut with washer (metric) that attaches posi- Terminal tive battery cable to post. Remove positive battery cable ring terminal. Detach solenoid connector [128]. Remove starter and gasket. Connector [128] Figure 5-11. Starter Wires 2002 Buell P3: Electric Starter 5-11...
Page 271: Testing Assembled Starter
Solenoid motor terminal to negative battery post. Solenoid relay terminal to positive battery post. Observe starter pinion. If starter pinion pulls in strongly, solenoid is working properly. If starter pinion does not pull in, replace the sole- noid. 5-12 2002 Buell P3: Electric Starter...
Page 272 If starter pinion returns to its original position, sole- Motor Terminal noid is working properly. If starter pinion does not return to its original posi- Relay Terminal tion, replace the solenoid. Battery Figure 5-15. Return Test 2002 Buell P3: Electric Starter 5-13...
Page 273 1/32 in. (0.794 mm) deep. The slots should then be cleaned to remove any dirt or cop- Figure 5-17. Removing the Thru-Bolts per dust. 6010 Field Frame Brush Holder Brush Spring (4) Armature Solenoid Housing Figure 5-18. Starter Components 5-14 2002 Buell P3: Electric Starter...
Page 274 6011 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. Figure 5-21. Grounded Armature Test 2002 Buell P3: Electric Starter 5-15...
Page 275 16. Remove drive (1), idler gear (2), idler gear bearing (3), and O-ring (4) from drive housing (O-ring is located in drive housing groove). 6012a Figure 5-25. Brush Holder Insulation Test Figure 5-22. Open Armature Test 5-16 2002 Buell P3: Electric Starter...
Page 276 10. Drive Housing 11. Solenoid Housing 12. Drive Assembly/ Overrunning Clutch 13. Idler Gear 14. Idler Gear Roller (5) 15. Idler Gear Bearing Cage 16. O-ring 17. Return Spring 18. Ball Figure 5-27. Starter Assembly 2002 Buell P3: Electric Starter 5-17...
Page 277 Bolts and Washers Connect battery cables, positive cable ﬁrst. TIghten ter- 13-20 ft-lbs minal hardware to 60-96 in-lbs (7-11 Nm). (17.6-27.1 Nm) 10. Install seat. See 2.28 SEAT. Figure 5-29. Starter Mounting (Primary Side) 5-18 2002 Buell P3: Electric Starter...
Page 278: Starter Solenoid
Replace wire connection hardware as Figure 5-30. 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). 2002 Buell P3: Electric Starter 5-19...
Page 279 HOME NOTES 5-20 2002 Buell P3: Electric Starter...
Page 280 DRIVE/TRANSMISSION 6 Table Of Contents SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Chain .
Page 282: Specifications
Steel plate (mm) 1.598 + 0.051 Clutch pack (in.) .413 in. (minimum) Clutch pack (mm) (16.787) MAXIMUM ALLOWABLE WARPAGE Friction plate (ﬁber) (in.) 0.0059 Friction plate (ﬁber) (mm) 0.150 Steel plate (in.) 0.0059 Steel plate (mm) 0.150 2002 Buell P3: Drive/Transmission...
Page 283 Remove debris from end, Page 6-10 LOCTITE® thread locker 262 (red), left hand threads, Transmission sprocket nut See NOTES See NOTES special torque turn method, Page 6-43 Transmission sprocket screws 90-110 in-lbs 10-12 Nm Replace after 3 removals, Page 6-44 2002 Buell P3: Drive/Transmission...
Page 284: Primary Chain
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 a0104x6x Figure 6-1. Primary Cover and Shifter Assembly 2002 Buell P3: Drive/Transmission...
Page 285 Figure 6-3. Primary Chain Adjuster Primary Chain Adjuster Figure 6-2. Remove primary cover. Loosen locknut from chain limiting screw. Turn limiting screw out of threaded boss in primary cover. Slide shoe outward and remove. Remove chain tensioner spring. 2002 Buell P3: Drive/Transmission...
Page 286 6.2 PRI- MARY CHAIN. Primary Chain Adjustment Figure 6-4. Buell Blast Models are shipped with a spacer Chain limiting screw between the primary chain limiting screw and the locknut. Spacer Jam nut The spacer is used to quickly get proper adjustment during production.
Page 287 Tighten pinch screw to 12-14 ft-lbs (16-19 Nm) 12. Install left footpeg support bracket. See 2.21 FOOT- PEGS AND FOOTPEG SUPPORT BRACKETS. 13. Connect negative battery cable to battery terminal. Tighten fastener to 60-96 in-lbs (7-11 Nm). 14. Install seat. See 2.28 SEAT. 2002 Buell P3: Drive/Transmission...
Page 288: Drive Belt
NOTE Condition 1 may develop into 2 or 3 over time. Condition 1 is not grounds for replacing the belt, but it should be watched closely before condition 2 develops which will require belt replacement. 2002 Buell P3: Drive/Transmission...
Page 289 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 2002 Buell P3: Drive/Transmission...
Page 290 14. Remove two TORX screws and washers from right side of rear inner fender. 15. Carefully bend rear inner fender upwards and remove drive belt. Discard drive belt. Sprocket Drive Belt Transmission Sprocket Sprocket Cover Figure 6-10. Secondary Drive Belt Assembly 2002 Buell P3: Drive/Transmission...
Page 291: Clutch
10. Install left footpeg support bracket. See 2.21 FOOT- PEGS AND FOOTPEG SUPPORT BRACKETS. 11. Connect negative battery cable to battery. Tighten fas- tener to 60-96 in-lbs (7-11 Nm). 12. Install seat. See 2.28 SEAT. 6-10 2002 Buell P3: Drive/Transmission...
Page 292 TORX screws with washers. Tighten in a crosswise pattern to 7-9 ft-lbs (10-12 Nm). 10. Check clutch cable freeplay. See Step 6 above. Figure 6-15. Adjusting Clutch Freeplay 11. Install footpeg support bracket. See 2.21 FOOTPEGS AND FOOTPEG SUPPORT BRACKETS. 2002 Buell P3: Drive/Transmission 6-11...
Page 293: Clutch Release Mechanism
18. Drain Plug and O-ring Spring 19. Seal Lockplate 20. Coupling Ramp Assembly Primary Cover Bushing 10. Spring 11. Chain Guide 12. Primary Cover Gasket 13. Pin 14. Shoe 15. Screw Figure 6-16. Clutch Release Mechanism 6-12 2002 Buell P3: Drive/Transmission...
Page 294 Connect negative battery cable to battery terminal. Tighten fastener to 60-96 in-lbs (6.8-10.9 Nm). Install seat. See 2.28 SEAT. Outer Ramp Slot of Primary Cover Adjusting Screw Cable End Coupling Figure 6-18. Nut & Outer Ramp 2002 Buell P3: Drive/Transmission 6-13...
Page 295: 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. 6-14 2002 Buell P3: Drive/Transmission...
Page 296 Pressure Plate Remove pressure plate assembly. Spring Seat Figure 6-23. Remove the clutch pack from the hub/ shell assembly. The pack consists of ﬁve ﬁber plates and Figure 6-21. Pressure Plate Assembly ﬁve steel plates. 2002 Buell P3: Drive/Transmission 6-15...
Page 297 10. Spring Seat 22. Clutch Hub 11. Diaphragm Spring 23. Retaining Ring 12. Retaining Ring 24. Bearing 13. Release Plate 25. Clutch Shell and Sprocket 14. Retaining Ring 26. Retaining Ring 15. Bearing Figure 6-22. Clutch Assembly 6-16 2002 Buell P3: Drive/Transmission...
Page 298 Remove and discard small retaining ring and Remove clutch pack components. See Steps 3-4 of then separate the adjusting screw from the bearing CLUTCH PACK under 6.6 PRIMARY DRIVE/CLUTCH. and release plate. Remove bearing from release plate. 2002 Buell P3: Drive/Transmission 6-17...
Page 299 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. 6-18 2002 Buell P3: Drive/Transmission...
Page 300 Place bearing inside release plate. Insert adjusting screw through bearing and release plate. Secure with new retaining ring. Figure 6-27. Position diaphragm spring with its concave side facing toward pressure plate onto pressure plate assembly. 2002 Buell P3: Drive/Transmission 6-19...
Page 301 Install left footpeg support bracket. See 2.21 FOOT- PEGS AND FOOTPEG SUPPORT BRACKETS. Figure 6-30. Mainshaft Nut and Washer Connect negative battery cable to battery terminal. Tighten fastener to 60-96 in-lbs (7-11 Nm). Install seat. See 2.28 SEAT. 6-20 2002 Buell P3: Drive/Transmission...
Page 302: Transmission
Neutral 1st Gear Mainshaft Mainshaft Countershaft Countershaft 3rd Gear 2nd Gear Mainshaft Mainshaft Countershaft Countershaft 5th Gear 4th Gear Mainshaft Mainshaft Countershaft Countershaft – Sliding member – Power ﬂow Figure 6-31. Transmission Power Flow 2002 Buell P3: Drive/Transmission 6-21...
Page 303: Transmission Case
Remove rear motor mount (9) and mounting hardware (10,11). 16. See Figure 6-34. Separate crankcase halves. 7691 7694 Figure 6-34. Splitting Crankcase Halves Detent Roller Arm TORX Screw Spring Retention Collar Figure 6-32. Countershaft Retainer 6-22 2002 Buell P3: Drive/Transmission...
Page 304 Washer - 3/8 I.D. X 13/16 O.D. (1) Nyloc, Hex Locknut - 3/8-16 Hex Socket Head Screw – 5/16-18 X 2-1/2 in. long (9) Rear Isolator 10. Screw (4) 11. Washer (4) Figure 3-35. Crankcase Hardware 2002 Buell P3: Drive/Transmission 6-23...
Page 305: Transmission Disassembly
REMOVER (2) (Part No. B-43895-1) to remove transmis- 7737 sion assembly from crankcase half. Remove crankcase from ﬁxture. Arbor Press Transmission Remover (Part no. B-43985-1) Crankcase Transmission Assembly Parallel Supports Figure 6-37. Transmission Remover/Installer on Fixture 6-24 2002 Buell P3: Drive/Transmission...
Page 306 15. Shifter Fork Pin (3) 16. Shifter Fork 4th Gear 17. Shifter Fork 1st & 2nd Gear 18. Shifter Fork 3rd & 5th Gear 19. Shifter Fork Drum 20. Neutral Indicator Pin Figure 6-38. Shifter Mechanism 2002 Buell P3: Drive/Transmission 6-25...
Page 307 Bearing (Outer) Oil Seal Right Crankcase Half Ball Bearing Retaining Ring Quad Seal Spacer 10. Oil Seal 11. Bearing (closed end) Shifter Drum 12. Bearing (closed end) Countershaft Figure 6-40. Transmission Assembly Right Crankcase Half 6-26 2002 Buell P3: Drive/Transmission...
Page 308 17. First Gear Countershaft 18. Countershaft 19. Third Gear Countershaft 20. Second Gear Countershaft 21. Fifth Gear Countershaft 22. Bearing 23. Retaining Ring 24. Countershaft Retainer 25. Screw Figure 6-41. Transmission Assembly Left Crankcase Half 2002 Buell P3: Drive/Transmission 6-27...
Page 309 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). 6-28 2002 Buell P3: Drive/Transmission...
Page 310: Transmission Assembly
Install mainshaft 3rd gear (13) onto shaft over bearing Install shifter forks and drum. See 6.10 TRANSMISSION (8). ASSEMBLY. 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). 2002 Buell P3: Drive/Transmission 6-29...
Page 311 17. First Gear Countershaft 18. Countershaft 19. Third Gear Countershaft 20. Second Gear Countershaft 21. Fifth Gear Countershaft 22. Bearing 23. Retaining Ring 24. Countershaft Retainer 25. Screw Figure 6-42. Transmission Assembly Left Crankcase Half 6-30 2002 Buell P3: Drive/Transmission...
Page 312 Secure pins in place with new cotter pins. Align shifter fork assembly with transmission gear fork grooves. This completes transmission assembly. Transmission compo- nents are now prepared for installation into the left crankcase half. 2002 Buell P3: Drive/Transmission 6-31...
Page 313 15. Shifter Fork Pin (3) 16. Shifter Fork 4th Gear 17. Shifter Fork 1st & 2nd Gear 18. Shifter Fork 3rd & 5th Gear 19. Shifter Fork Drum 20. Neutral Indicator Pin Figure 6-44. Shifter Mechanism 6-32 2002 Buell P3: Drive/Transmission...
Page 314: Main Drive Gear
0.315-0.285 in. 5th gear (8.001-7.239 mm) For outer Driver bearing Thrust washer For seal 0.06-0.03 in. (1.52-0.76 mm) Figure 6-47. Removing Main Drive Gear Main drive gear Needle bearing Seal Figure 6-45. Main Drive Gear Assembly 2002 Buell P3: Drive/Transmission 6-33...
Page 315 (4) bottoms against inner race Thrust Washer of bearing. Bolt Figure 6-45. Tap in new seal (3) at threaded end of Installer Cup 5th gear. 5th Gear Washer Figure 6-49. Main Drive Gear Installation 6-34 2002 Buell P3: Drive/Transmission...
Page 316: Right Transmission Case Bearings
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. 2002 Buell P3: Drive/Transmission 6-35...
Page 317 Needle Bearing (2) Oil Seal Right Crankcase Half Ball Bearing Retaining Ring Quad Seal Spacer 10. Oil Seal 11. Bearing (closed end) Shifter Drum 12. Bearing (closed end) Countershaft Figure 6-52. Transmission Assembly Right Crankcase Half 6-36 2002 Buell P3: Drive/Transmission...
Page 318: 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. 2002 Buell P3: Drive/Transmission 6-37...
Page 319 17. First Gear Countershaft 18. Countershaft 19. Third Gear Countershaft 20. Second Gear Countershaft 21. Fifth Gear Countershaft 22. Bearing 23. Retaining Ring 24. Countershaft Retainer 25. Screw Figure 6-55. Transmission Assembly Left Crankcase Half 6-38 2002 Buell P3: Drive/Transmission...
Page 320: Transmission Installation
(red) to last few threads. Assembly Tighten 1/4-in. fasteners to 80-110 in-lbs (9.0- 12.4 Nm) Tighten 5/16-in. fasteners to 15-19 ft-lbs (20- Figure 6-57. Transmission Remover/Installer on Fixture 25 Nm). 7694 Figure 6-58. Crankcase Halves 2002 Buell P3: Drive/Transmission 6-39...
Page 321 Washer - 3/8 I.D. X 13/16 O.D. (1) Nyloc, Hex Locknut - 3/8-16 Bottom Case T40 TORX Bolt – 5/16-18 X 3-1/2 in. long (9) Rear Isolator 10. Screw (4) 11. Washer (4) Figure 6-59. Crankcase Hardware 6-40 2002 Buell P3: Drive/Transmission...
Page 322: Shifter Pawl Adjustment
(blue) to last few threads. Figure 6-61. Shifter Shaft Assembly Alignment Insert screw (1) through retention collar (2) and thread into end of shaft. Place transmission in gear, and tighten TORX screw (1) to 13-17 ft-lbs (18-23 Nm) torque. 2002 Buell P3: Drive/Transmission 6-41...
Page 323 HOME 7691 TORX Screw Retention Collar Detent Roller Arm Spring Figure 6-62. Countershaft Retainer 6-42 2002 Buell P3: Drive/Transmission...
Page 324: Transmission Sprocket
If you cannot align lockplate and sprocket screw holes, nut may be additionally tightened 45° as speciﬁed above. Tightening too much or too little may cause the nut to come loose during vehicle opera- tion. 2002 Buell P3: Drive/Transmission 6-43...
Page 325 (Part No. HD-94660-37B) Fill transmission to proper level with fresh lubricant. See CLUTCH. Figure 6-65. Transmission Sprocket Tightening a0163x6x Transmission Transmission Sprocket Sprocket Nut 45° 30° Line scribed on nut and sprocket Figure 6-66. Aligning Transmission Sprocket 6-44 2002 Buell P3: Drive/Transmission...
Page 326 ELECTRICAL Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 328: Specifications
67713-86 Tail/Stop Lamp 5/21 0.42/1.75 Y0401B.2U Marker lamps Turn Signal Lamp, Front and Rear 0.83 68968-99Y (1 bulb each) High Beam Indicator Turn Signal Indicator Indicator lamps Non-replacable LEDs (in speedometer) Oil Pressure Indicator Neutral Indicator 2002 Buell P3: Electrical...
Page 329 25-28 in-lbs 2.6-3.2 Nm metric, Page 7-50 Throttle position sensor fasteners 12-23 in-lbs 2-3 Nm Page 7-12 Timing inpection hole plug 10-15 ft-lbs 14-20 Nm Page 7-21 Voltage regulator mounting fasteners. 4-6 ft-lbs 5-8 Nm Page 7-42 2002 Buell P3: Electrical...
Page 330: Ignition System
Connector [88] Bank Angle Sensor Auto Enrichener Connector [10] 10R12 Spark Plug 11-18 ft-lbs (14.9-24.4 Nm) Throttle Position Sensor (TP Sensor) Rotor Cup Timer Cover Module Plate (Ignition Module/Cam Position Sensor) a0217a7x Figure 7-1. Ignition System Components 2002 Buell P3: Electrical...
Page 331 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 2002 Buell P3: Electrical...
Page 332 2002 Buell P3: Electrical...
Page 333: Diagnostic Charts
Repair / Replace Engine Between Coil and [22A]. Stop Switch or Wiring. 5002 5173 Wire Harness Connectors DESCRIPTION TYPE LOCATION [22] RT Handlebar 4 - Place Multilock Behind Headlight Switch Figure 7-4. No Spark At Spark Plug 2002 Buell P3: Electrical...
Page 334 Go To Next Page Use harness connector adaptor kit (HD-41404) Repair Open In W/BK Wire Repair Open Between [10B] gray female probe(s) and Pin 6 (BK) And Ground patch cord. 5003 5003 Figure 7-5. No Spark At Spark Plug 2002 Buell P3: Electrical...
Page 335 Inspect For Mechanical Failure. Module. Repair. 5009 5005 3 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 2002 Buell P3: Electrical...
Page 336 Bank Angle Sensor Damage. Repair If Neces- Repair Short To Ground sary. On LT GN/GY Wire. If Harness Is Not Damaged, Replace Ignition Module. 5007 Connector [134] 5009 Figure 7-7. Continuous or No Spark At Spark Plug 2002 Buell P3: Electrical...
Page 337 Are Ferrous Metals Located Install Properly Within 1/4” Of Sides, Face, Or Top Of Bank Angle Sensor? Return To Origi- nal Conﬁguration. Replace Bank Angle Sensor. 5013 Figure 7-8. Continuous or No Spark At Spark Plug 7-10 2002 Buell P3: Electrical...
Page 338 Check continuity between Breakout Box Repair Open Pin 3 and connector [88B] pins 3 and 4. Continuity Present? 7610 Replace Repair Open TP Sensor 7580 7590 Remove seat and fuel tank cover. See 2.31 SEAT. Figure 9. Drivability Troubleshooting 2002 Buell P3: Electrical 7-11...
Page 339: Throttle Position Sensor
After WOT, the TPS reading may not return back to exactly 0.5V +/- 0.05V. To re-check exact TPS voltage reading, turn cycle key off and on. Tighten TP Sensor mounting screws to 13-23 in-lbs (2-3 Nm). 7-12 2002 Buell P3: Electrical...
Page 340: Bank Angle Sensor
Install circuit breaker to circuit breaker mounting bracket. Install negative battery cable to battery terminal. Tighten fastener to 60-96 in-lbs (7-11 Nm). Install seat. See 2.28 SEAT. 8261 Locknut Bank Angle Sensor Connector [134] Figure 7-11. Bank Angle Sensor Removal 2002 Buell P3: Electrical 7-13...
Page 341: Ignition/Headlamp Key Switch
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. 7-14 2002 Buell P3: Electrical...
Page 342 Figure 7-14. Ignition Key Switch Connector [33] Turn ignition key switch to OFF. Check all functions listed in the table on page 5-14. Turn ignition key switch to IGN. Start motorcycle. See Section 4. Turn ignition key switch to LOCK. 2002 Buell P3: Electrical 7-15...
Page 343: Auto Enrichener
7-15. AUTO-ENRICHENER/TP SENSOR 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 Figure 7-15. TP Sensor/Auto-Enrichener Connector [88] 7-16 2002 Buell P3: Electrical...
Page 344 Module 7505 7516 Use black male probe and patch cord from harness adaptor kit (HD-41404) Replace fuse. Locate and repair short 7517 to ground on Orange wire. Replace fuse. 7510 Figure 7-16. Driveability Troubleshooting 2002 Buell P3: Electrical 7-17...
Page 345: Ignition Module/Cam Position Sensor
Figure 7-18. Drill hole in outer timer cover at 5:00 position approximately 1/2 inch (13 mm) in from outside edge. Pull out outer timer cover using 90 degree pick or other suitable tool. 7-18 2002 Buell P3: Electrical...
Page 346 (1.5-2.6 Nm) Screw Rotor Cup Timer Cover 43-53 in-lbs (4.9-6.0 Nm) Integrated Ignition Module with Cam Position Sensor Module Plate Screws (2) a0277x7x (Module Plate) 15-30 in-lbs (1.7-3.4 Nm) Figure 7-19. Ignition Module/Cam Position Sensor 2002 Buell P3: Electrical 7-19...
Page 347 Check ignition timing. See IGNITION TIMING. 10. Tighten module plate screws to 10-20 in-lbs (1-2 Nm). *Lt Green/ To Sidestand Interlock Grey [10A] 11. Install new outer timer cover. *Tan/Yellow [10B] Black Ground Figure 7-20. Ignition Connector [10] 7-20 2002 Buell P3: Electrical...
Page 348 Tighten module plate screws to 10-20 in-lbs (1-2 Nm) 11. Install new outer cover, if removed. 12. Remove TIMING MARK VIEW PLUG from timing inspection hole. Install hex socket timing plug. Torque timing plug to 10-15 ft. lbs (14-20 Nm). 2002 Buell P3: Electrical 7-21...
Page 349 10. Install new outer cover. 11. Install timing plug. Tighten plug to 10-15 ft-lbs (14-21 Nm). 12. If possible, dynamically time engine as well to verify that system is functioning properly. See DYNAMIC TIMING. Begin at step 2. 7-22 2002 Buell P3: Electrical...
Page 350: Ignition Coil
Normal resistance range is 7,720-9,440 ohms. Normal resistance range is 0.4-0.6 ohms. TEST RESULTS on the next page if resistance TEST RESULTS on the next page if resistance is not within normal operating range. is not within normal operating range. 2002 Buell P3: Electrical 7-23...
Page 351 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. 7-24 2002 Buell P3: Electrical...
Page 352: Spark Plug Cables
Replace cables not meeting resistance speciﬁcations. ● 2,375-5,833 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. 2002 Buell P3: Electrical 7-25...
Page 353: Starter/Ignition Interlock
This system will prevent vehicle operation if for- ward motion is attempted with the side stand down. See Ignition Tests on following pages. Use harness connector adaptor kit (HD-41404) gray male probe and patch cord. 2002 Buell P3: Electrical 7-26...
Page 354 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 2002 Buell P3: Electrical 7-27...
Page 355 Test the switch using an ohmmeter. engaged. Test the switch as follows: With side stand down (switch open), the switch should show ∞ ohms (inﬁnite ohms). Unplug the 2-place clutch switch connector [95]. 7-28 2002 Buell P3: Electrical...
Page 356 2002 Buell P3: Electrical 7-29...
Page 357 To test/replace the neutral switch, see 7.23 NEUTRAL INDI- CATOR SWITCH. Nut (2) Connector [60] Figure 7-33. Side Stand Switch a0231x7x Trigger Button Clutch Engaged (switch open) Clutch Disengaged (switch closed) Connector [95] Figure 7-34. Clutch Switch 7-30 2002 Buell P3: Electrical...
Page 358 The ignition fuse is in the fuse block under the seat. Always replace the fuse with another 7.5 ampere fuse. 7803 TN/Y TN/Y TN/W TN/GR R/BK System Relay [61] Connector [171] Figure 7-38. Fuse Block Figure 7-35. System Relay 2002 Buell P3: Electrical 7-31...
Page 359 Check diode polarity as shown in Figure 7-40. Replace diodes as necessary. Continuity Infinite ohms Figure 7-39. Ohmmeter Diode Test a0236x7x TN/W TN/Y Diode 1 polarity TN/GN TN/Y Diode 2 polarity Figure 7-40. Diode Polarity 7-32 2002 Buell P3: Electrical...
Page 360: 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. 2002 Buell P3: Electrical 7-33...
Page 361: 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 2002 Buell P3: Electrical...
Page 362 Damaged or Perform CURRENT OUTPUT Fail very slowly for long periods. slipping rotor. TEST. Battery self-discharge and/or acces- 5319 sory draw because vehicle was not operated for a long period. Figure 7-44. Charging System Troubleshooting 2002 Buell P3: Electrical 7-35...
Page 363 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 2002 Buell P3: Electrical...
Page 364 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 tie. 2002 Buell P3: Electrical 7-37...
Page 365 Test for resistance with ohmmeter set on the RX1 scale. Figure 7-50. Check for Stator Resistance 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. 7-38 2002 Buell P3: Electrical...
Page 366 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 2002 Buell P3: Electrical 7-39...
Page 367: Alternator
*TORX Screws (4) Rotor 30-40 in-lbs (3.4-3.5 Nm) Remove stator wiring grommet from left crankcase half. * Do not reuse Withdraw stator wiring from grommet hole in left crank- Figure 7-54. Stator Assembly case half. Remove stator. 7-40 2002 Buell P3: Electrical...
Page 368 Cable tie connector [46] halves together. NOTE Temporarily attach a thin ﬂexible “feed” or mechanic’s wire to the connector end of the stator wiring to assist in the routing of the wiring. 2002 Buell P3: Electrical 7-41...
Page 369: Voltage Regulator
Install seat. See 2.28 SEAT. Connect negative battery cable to battery terminal. TIghten fastener to 60-96 in-lbs (7-11 Nm). Test charging system. See 7.13 CHARGING SYSTEM. 7-42 2002 Buell P3: Electrical...
Page 370: Battery
HOME BATTERY 7.16 GENERAL Warning All 2001 Model Year Buell batteries are permanently sealed, Label 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 371: Disconnection And Removal
Accidental electrolyte leakage will damage Safety Precautions motorcycle parts. Never charge a battery without ﬁrst reviewing the instructions Install the battery on the motorcycle. See BATTERY, for the charger being used. In addition to the manufacturer’s INSTALLATION AND CONNECTION. 7-44 2002 Buell P3: Electrical...
Page 372 Positive battery cable runs from the starter post to the posi- tive battery terminal. Negative battery cable runs from frame to negative battery terminal. NOTE: route negative battery cable between battery and frame rail. Pads (4) Boot Figure 7-62. Battery Installation 2002 Buell P3: Electrical 7-45...
Page 373 99863-93TA) may be used to maintain battery charge for extended periods of time without risk of overcharging or boil- ing. When returning a battery to service after storage, refer to the instructions under CHARGING BATTERY. 7-46 2002 Buell P3: Electrical...
Page 374: Headlamp
Attach both front turn signals. See 7.19 TURN SIG- Tighten screws to 12-14 in-lbs (1-2 Nm). NALS. Install windscreen if removed with four screws and Install windscreen with four screws and washers. See washers. See 2.26 WINDSCREEN. 2.26 WINDSCREEN. 2002 Buell P3: Electrical 7-47...
Page 375 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). 10. Adjust headlamp if necessary. See ADJUSTMENT. 7-48 2002 Buell P3: Electrical...
Page 376 Horizontal Headlamp Adjuster Figure 7-67. Turn vertical headlamp mounting adjuster clockwise to raise beam height. Figure 7-67. Turn horizontal headlamp mount- Figure 7-67. Headlamp Vertical/Horizontal Adjusters ing adjuster clockwise to change lateral alignment. 2002 Buell P3: Electrical 7-49...
Page 377: 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. 7-50 2002 Buell P3: Electrical...
Page 378: Turn Signals
Front and rear left turn signals must ﬂash. Screw Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Figure 7-71. Rear Turn Signals Turn ignition key switch to OFF. 2002 Buell P3: Electrical 7-51...
Page 379 Activate left turn signals using switch on left handle- bar. Front and rear left turn signals must ﬂash. Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. 7-52 2002 Buell P3: Electrical...
Page 380: 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. 2002 Buell P3: Electrical 7-53...
Page 381: Handlebar Switches
Attach connector [170] and connec- 7809 tor [22] to wiring harness. Fasten wiring harness behind dash with new cable straps. Adjust throttle cables. See 1.18 THROTTLE CABLES. Ignition OFF Ignition ON Electric Starter Switch Figure 7-75. Right Handlebar Switches 7-54 2002 Buell P3: Electrical...
Page 382 7079 Check left and right turn signals. Activate horn by pressing horn switch. Turn ignition key switch to OFF. Passing Lamp HIGH Beam LOW Beam Turn Signals Horn Figure 7-77. Left Handlebar Switches 2002 Buell P3: Electrical 7-55...
Page 383: Horn
If horn is faulty, replace unit as an assem- bly. 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. 7-56 2002 Buell P3: Electrical...
Page 384: Neutral Indicator Switch
Install switch in crankcase. Tighten to 3-5 ft-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 6.16 TRANS- MISSION SPROCKET. Install sprocket cover. See 2.22 SPROCKET COVER. 2002 Buell P3: Electrical 7-57...
Page 385: Fuses And Circuit Breakers
HOME FUSES AND CIRCUIT BREAKERS 7.24 GENERAL a0072aox Buell motorcycles feature two components which protect the electrical system; Fuses and Circuit Breakers. Fuses Figure 7-81. The fuse block is on the right side of the frame under the seat. The block contains ﬁve replaceable fuses.
Page 386: 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. 2002 Buell P3: Electrical 7-59...
Page 387 Position dash panel in mounting position on upper triple clamp and install two screws. Tighten screws to 30-36 in-lbs (3-4 Nm). Figure 7-84. Speedometer Fasteners 7749 Figure 7-85. Removing Speedometer 7-60 2002 Buell P3: Electrical...
Page 388: Speedometer Sensor
After installing seat, pull upward on front of seat to be sure it is locked in position. If seat is loose, it could shift Figure 7-87. Speedometer Sensor during vehicle operation, causing loss of control of vehi- cle and death or serious injury. 2002 Buell P3: Electrical 7-61...
Page 389: 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). 7-62 2002 Buell P3: Electrical...
Page 390 Sweep tool has frequency jumps in full scale sweeps. Perform sweep in 3 stages as described in speedometer tester manual. a0263x7x Disconnecting speed sensor or install speedometer sen- Figure 7-90. Test Harness sor will cause code d02 to set. 2002 Buell P3: Electrical 7-63...
Page 391 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 7-91. Speedometer Test Chart 1 7-64 2002 Buell P3: Electrical...
Page 392 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 7-92. Speedometer Test Chart 2A 2002 Buell P3: Electrical 7-65...
Page 393 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 6029 speedometer. 6024 Figure 7-93. Speedometer Test Chart 2B 7-66 2002 Buell P3: Electrical...
Page 394: 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 7-94. Diagnostics 2002 Buell P3: Electrical 7-67...
Page 395: Main Wiring Harness
17. Disconnect starter connector [128] at starter solenoid. 18. See Figure 7-95. Disconnect ignition connector [10] on left side of frame backbone. Figure 7-97. TP Sensor/Auto-Enrichener Connector [88] 19. Feed harness through frame and upper tie bar mount. 7-68 2002 Buell P3: Electrical...
Page 396 13. Install hose clamp around hoses and oil pressure switch and neutral switch wires. Secure clamp with new lock- nut. 14. Attach main wiring harness to T-studs. 15. Feed wire harness through upper tie bar mount in two bundles. 2002 Buell P3: Electrical 7-69...
Page 397 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. 7-70 2002 Buell P3: Electrical...
Page 398 HOME 2002 Buell P3: Electrical 7-71...
Page 399 Table Of Contents SUBJECT PAGE NO. A.1 TOOLS ............B.1 ELECTRICAL CONNECTORS .
Page 400 Product...

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Buell blast p3 2001

Buell 2002 P3 Service Manual

Maintenance 1

Chassis 2

Table of Contents

Engine 3

Fuel System 4

Electric Starter 5

Drive/Transmission 6

Electrical 7

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