General - Buell 2002 P3 Service Manual

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GENERAL

SERVICING A NEW MOTORCYCLE
11 1
WARNING
Always follow the listed service and maintenance recom-
mendations, because they affect the safe operation of
the motorcycle and the personal welfare of the rider. Fail-
ure to follow recommendations could result in death or
serious injury.
Service operations to be performed before customer delivery
are specified in the applicable model year PREDELIVERY
AND SETUP MANUAL.
The performance of new motorcycle initial service is required
to keep warranty in force and to ensure proper emissions sys-
tems operation.
After a new motorcycle has been driven its first 1000 miles
(1600 km) and every service interval thereafter, have a Buell
dealer perform the service operations listed in
SAFE OPERATING MAINTENANCE
CAUTION
●
Do not attempt to retighten engine head bolts.
Retightening can cause engine damage.
●
During the initial 500 mile (800 km) break-in period,
use only Harley-Davidson 20W50 engine oil. Failure
to use the recommended oil will result in improper
break-in of the engine cylinders and piston rings.
A careful check of certain equipment is necessary after peri-
ods of storage, and frequently between regular service inter-
vals, to determine if additional maintenance is required.
Check:
1. Tires for abrasions, cuts and correct pressure.
2. Drive belt for proper tension and condition.
3. Brakes, steering and throttle for responsiveness.
4. Brake fluid level and condition. Hydraulic lines and fit-
tings for leaks. Also, check brake pads and rotors for
wear.
5. Cables for fraying, crimping and free operation.
6. Engine oil and transmission fluid levels.
7. Headlamp, passing lamp, tail lamp, brake lamp and turn
signal operation.
SHOP PRACTICES
Repair Notes
NOTE
●
General maintenance practices are given in this section.
●
Repair = Disassembly/Assembly.
●
Replace = Removal/Installation.
WARNING
Table 1-1.
All special tools and torque values are noted at the point of
use.
All required parts or materials can be found in the appropriate
PARTS CATALOG.
Safety
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection14
. Don't just do the job – do the job safely.
Removing Parts
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
the part should be equal and parallel and should be posi-
tioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air. Always use blocking or
proper stands to support the part that has been hoisted.
If a part cannot be withdrawn, verify that all fastening hard-
ware has been detached. Check to see if any parts are in the
way of the part being removed.
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
Cleaning
If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before reassembly. Keep all dirt
out of parts. Seals, filters and covers are used in this vehicle
to keep out environmental dirt and dust. These items must be
kept in good condition to ensure satisfactory operation.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other mate-
rial. Be sure the part is clean when it is installed.
Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust
and debris.
Disassembly and Assembly
Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished.
Be sure that everything is done.
Operate the vehicle to perform any final check or adjust-
ments. If all is correct, the vehicle is ready to go back to the
customer.
Checking Torques on Fasteners with Lock
Patches/Loctite Threadlocker
To check the torque on a fastener that has a lock patch do the
following:
2002 Buell P3: Maintenance
1.1
1-1