Buell 2002 S3T Service Manual

Table of Contents

Quick Links

Download this manual

2002 BUELL S3T

SERVICE MANUAL

Part Number 99489-02Y

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

Need help?

Do you have a question about the 2002 S3T and is the answer not in the manual?

Questions and answers

Summary of Contents for Buell 2002 S3T

Page 1 2002 BUELL S3T SERVICE MANUAL Part Number 99489-02Y 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 APPENDIX A–TOOLS Part No. B-35316-5 12 Inch Bolt. Part No. B-42887 Brake Caliper Piston Remover Used with Part No. HD-39302. Part No. B-41174 Rear Wheel Support Stand and Part No. B-43721 Front Fork Seal Driver Part No. B-41174-2 Replacement Pad Part No.
Page 4 HOME Part No. B-45110 Shock Preload Adjustment Tools Part No. HD-23738 Vacuum Pump Part No. B-59000A Pro Level Oil Gauge Part No. HD-25070 Robinair Heat Gun Part No. HD-01289 Rim Protectors Part No. HD-26792 Spark Plug Tester Part No. HD-21000 Tire Spreader Part No.
Page 5 HOME Part No. HD-33067 Wheel Bearing Packer Part No. HD-33446A Cylinder Torque Plates and Torque Plate Bolts Part No. HD-33446-86 Part No. HD-33223-1 Cylinder Compression Gauge Part No. HD-34623B Piston Pin Retaining Ring Installer/Remover Part No. HD-33416 Universal Driver Handle Part No.
Page 6 HOME Part No. HD-34730-2C Fuel Injector Test Lamp Part No. HD-34751 Nylon Valve Guide Brush Part No. HD-34731 Shoulderless Valve Guide Part No. HD-34813 Rowe Flywheel Rebuilding Jig Installation Tool Part No. HD-34736B Valve Spring Compressor Part No. HD-34816 Oil Pressure Switch Wrench Part No.
Page 7 HOME Part No. HD-35316-A Main Drive Gear Remover/Installer Part No. HD-35518 Internal/External and Main Drive Gear Bearing Installer Retaining Ring Pliers 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...
Page 8 HOME Part No. HD-37404 Countershaft Gear Support Plate Part No. HD-38125-8 Packard Terminal Crimp Tool Part No. HD-37842A Inner/Outer Main Drive Gear Part No. HD-38361 Cam Gear Gauge Pin Set Needle Bearing Installer (0.108 in. (2.74 mm) Diameter) Part No. HD-38125-6 Packard Terminal Crimp Tool Part No.
Page 9 HOME Part No. HD-38871 Camshaft Bushing Plate Pilot Part No. HD-39458 Sprocket Shaft Bearing Outer and Reamer Race Installer Part No. HD-39151 Shift Drum Retaining Ring Installer Part No. HD-39565 Engine Sound Probe Part No. HD-39301A Steering Head Bearing Part No. HD-39617 Inductive Amp Probe. Race Remover Use with HD-35500A.
Page 10 HOME Part No. HD-39621-27 Socket Terminal Remover Part No. HD-39800 Oil Filter Crusher, Small Part No. HD-39621-28 Pin Terminal Remover 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.
Page 11 HOME Part No. HD-39964 Reamer Lubricant (Cool Tool) Part No. HD-39994 Paint Repair Kit Part No. HD-39965 Deutsch Terminal Crimp Tool Part No. HD-41025 Tool Organizational System Part No. HD-39969 Ultra-Torch UT-100 Part No. HD-41137 Hose Clamp Pliers Part No. HD-39978 Fluke 78 Multimeter (DVOM) Part No.
Page 12 HOME Part No. HD-41182 Fuel Pressure Gauge Part No. HD-41321 Sprocket Holding Tool Part No. HD-41183 Heat Shield Attachment Part No. HD-41325 Scanalyzer and Use with Part No. HD-25070. Part No. HD 41325-99 Cartridge Part No. HD-41185 Hose Cutting Tool Part No.
Page 13 HOME Part No. HD-41506 Crankshaft Locking Tool Part No. HD-42311 Oil Filter Wrench Part No. HD-41609 Amp Terminal Crimp Tool Part No. HD-42320 Piston Pin Remover/Installer Part No. HD-41675 Oil Pressure Sending Unit Wrench Part No. HD-42322 Piston Support Plate Made in USA PP-9606- 0001 Part No.
Page 14 HOME Part No. HD-42579 Sprocket Bearing/Seal Installer Part No. HD-44069 Timken Snap Ring Remover/Installer Part No. HD-42774 Sprocket Shaft Seal Installer Part No. HD-44358 Flywheel Fixture (2000 Models) Part No. HD-42682 Breakout Box Part No. HD-44404 Sprocket Shaft Inner Timken Bearing Remover Part No.
Page 15 HOME Part No. HD-94547-101 Crankshaft Bearing Outer Race Part No. HD-94804-57 Rocker Arm Bushing Reamer Remover/Installer Part No. HD-94660-37B Mainshaft Locknut Wrench Part No. HD-94812-1 Pinion Shaft Bushing Reamer. Use with HD-94812-87. Part No. HD-94800-26A Connecting Rod Bushing Part No. HD-94812-87 Pinion Shaft Reamer Pilot. Reamers and Pilots Use with HD-94812-1.
Page 16 HOME Part No. HD-95635-46 All-Purpose Claw Puller Part No. HD-95970-32D Piston Pin Bushing Tool Part No. HD-95637-46A Wedge Attachment for Part No. HD-96215-49 Small Internal Retaining Claw Puller. Use with HD-95635-46. Ring Pliers Part No. HD-95760-69A Bushing/Bearing Puller Tool Set. Part No.
Page 17 HOME Part No. HD-96550-36A Valve Lapping Tool Part No. HD-96740-36 Connecting Rod Lapping Arbor Part No. HD-96650-80 Flywheel Truing Stand Part No. HD-96796-47 Valve Spring Tester Part No. HD-96710-40B Crankcase Main Bearing Part No. HD-96921-52A Oil Pressure Gauge Lapping Tool Part No.
Page 18 HOME Part No. HD-97087-65B Hose Clamp Pliers Part No. HD-99500-80 Wheel Truing and Balancing Stand Part No. HD-97292-61 Two Claw Puller Part No. J-5586 Transmission Shaft Retaining Ring Pliers A-16 Appendix B, Wiring...
Page 19 HOME APPENDIX B - ELECTRICAL CONNECTORS GENERAL The following table provides a brief description of the connec- tors found on the S3T Thunderbolt. Connector numbers are listed in [brackets] in this manual. Table B-1. Electrical Connectors Connector Component(s) Description [10] Electronic Control Module (Black) 12-place Deutsch [11]...
Page 20: Deutsch Electrical Connectors
HOME DEUTSCH ELECTRICAL CONNECTORS GENERAL b0070x7x The Deutsch Connector features a superior seal to protect electrical contacts from dirt and moisture in harsh environ- ments. Three and eight pin connectors are of similar construction with one exception: eight pin connectors use two external latches on the socket side.
Page 21 HOME face straight upward. When correctly positioned, the x0014a7x locking bar ﬁts snugly in the space between the contact band and the core crimp tails. Strip lead removing 5/32 in. (4.0 mm) of insulation. Insert Housing wires between crimp tails until ends make contact with locking bar.
Page 22: Amp Multilock Electrical Connectors
HOME AMP MULTILOCK ELECTRICAL CONNECTORS REMOVING SOCKET/PIN Figure B-5. With the ﬂat edge against the terminal, insert the pick (Snap-On TT600-3) into the cavity until it TERMINALS stops. Pivot the end of the pick away from the terminal and gently tug on wire to pull terminal from chamber. Do If necessary, cut any surrounding cable straps to gain not tug on the wire until the tang is released or the termi- access to the connector.
Page 23 HOME INSTALLING SOCKET/PIN terminal (on the side opposite the crimp tails) must face downward. On the socket side, tangs are at the top of each TERMINALS chamber, so the socket terminal slot (on the same side as the crimp tails) must face upward. Up and down can be deter- mined by the position of the release button (used to separate NOTE the pin and socket halves), the button always being the top of...
Page 24 HOME CRIMPING INSTRUCTIONS b0238x7x Figure B-7. 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 Raise locking bar by pushing up on bottom ﬂange. With locking tool.
Page 25 HOME APPENDIX C–METRIC CONVERSIONS Table C-1. 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...
Page 26 WARNING WARNING Torque speciﬁcations for speciﬁc components are listed in The quality fasteners used on Buell motorcycles have each section at the point of use. When converting to Newton- speciﬁc strength, ﬁnish and type requirements to per- meters, use the formulas given under the metric chart. For all...
Page 27: Table Of Contents
MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fluid Requirements .
Page 29: General
(800 km), and at every 2500 mile (4000 km) interval thereaf- forming any job. Be sure you have a complete understanding ter, have a Buell dealer perform the service operations listed of the task to be performed. Use common sense. Use the Table 1-3.
Page 30: Repair And Replacement Procedures
Spinning bearings with compressed air can also cause a Always check gears for damaged or worn teeth. bearing to ﬂy apart, which may result in minor or moder- ate injury. Lubricate mating surfaces before pressing gears on shafts. 2002 Buell S3T: Maintenance...
Page 31: Tool Safety
When using leak dye with the black light leak detector, add ● Wear approved eye protection when using these tools. 1/4 oz. (7.4 ml) of dye for each 1 quart (0.9 l) of ﬂuid in the ● system being checked. Protect bystanders with approved eye protection. 2002 Buell S3T: Maintenance...
Page 32: Storage Units
● When breaking loose a fastener, apply a small amount of pressure as a test to be sure the ratchet’s gear wheel is engaged with the pawl. 2002 Buell S3T: Maintenance...
Page 33: Fluid Requirements
4. The preferred viscosities for the diesel engine oils, in descending order, are 20W-50, 15W-40 and 10W-40. At the BRAKE FLUID ﬁrst opportunity, see a Buell dealer to change back to 100 percent Harley-Davidson oil. Table 1-2. Recommended Oil Grades...
Page 34 2002 Buell S3T: Maintenance...
Page 35 2002 Buell S3T: Maintenance...
Page 36 2002 Buell S3T: Maintenance...
Page 37 2002 Buell S3T: Maintenance...
Page 38 HOME NOTES 1-10 2002 Buell S3T: Maintenance...
Page 39: Battery
HOME BATTERY GENERAL f1730x8x Buell motorcycle batteries are permanently sealed, mainte- nance-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 40 Inspect the battery for discoloration, raised top or a warped or distorted case, which might indicate that the battery has been frozen, overheated or overcharged. Inspect the battery case for cracks or leaks. 1-12 2002 Buell S3T: Maintenance...
Page 41 Install battery strap locknut on threaded shaft. Tighten to 40 in-lbs (4.5 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Secure oxygen sensor connector with new cable straps. Install seat. See 2.35 SEAT. 2002 Buell S3T: Maintenance 1-13...
Page 42: Engine Lubrication System
Above 40 H.D. Multi-Grade HD 360 Good are 20W-50, 15W-40 and 10W-40. At the ﬁrst opportu- 20W50 (4°C) nity, see a Buell dealer to change back to 100 percent ° Above 60 H.D. Regular Heavy HD 360 Poor Harley-Davidson oil.
Page 43 1000 RPM or above. 13. Check for oil leaks at oil ﬁlter and drain hose. 14. Check oil level. See CHECKING ENGINE OIL LEVEL. 2002 Buell S3T: Maintenance 1-15...
Page 44: Brakes
Failure to comply may result in cosmetic dam- age. NOTE Hydraulic brake ﬂuid bladder-type pressure equipment can be used to ﬁll the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pressurization. 1-16 2002 Buell S3T: Maintenance...
Page 45 Remove cap and gasket from rear master cylinder reservoir. Bring ﬂuid level to between upper and lower marks on reservoir. See Figure 1-12. Depress, release and then hold brake lever/pedal to build up hydraulic pressure. 2002 Buell S3T: Maintenance 1-17...
Page 46: Rear Brake Pedal
Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. Check rear brake pedal height.
Page 47: Shift Linkage Rod Adjustment
Tighten to 59-66 in-lbs (6.6-7.5 Nm). Check for proper shift lever/clutch operation. Upper Eye Fastener Upper Eye Jamnut Shift Rod Shift Linkage Rod Measurement (eye center to eye center) Figure 1-15. Shift Linkage Rod Adjustment 2002 Buell S3T: Maintenance 1-19...
Page 48: Brake Pads And Rotors
The brake rotor must be within the following speciﬁca- tions. If the brake rotor is suspected of being damaged, inspect rotor using the following measurements: ● Lateral Movement: 0.5 mm ● Radial Movement: 0.45 mm ● Rotational Movement: 0.39 mm 1-20 2002 Buell S3T: Maintenance...
Page 49: Tires And Wheels
At every 10,000 mile (16,000 km) service interval. ● When storing or removing the motorcycle for the season. Check wheel bearings and axle spacers for wear and corro- sion. Excessive play or roughness indicates worn bearings. Replace bearings in sets only. 2002 Buell S3T: Maintenance 1-21...
Page 50: Clutch
Figure 1-19. Fluid Level Figure 1-18. Install clutch inspection cover (2) using four TORX screws with washers (1). Tighten in a cross- wise pattern to 7-9 ft-lbs (10-12 Nm). Install mufﬂer. See 2.27 EXHAUST SYSTEM. 1-22 2002 Buell S3T: Maintenance...
Page 51 Install clutch inspection cover (2) using four TORX screws with washers (1). Tighten in a cross- wise pattern to 7-9 ft-lbs (10-12 Nm). Figure 1-22. Adjusting Clutch Freeplay Check clutch cable freeplay. See Step 6 above. 2002 Buell S3T: Maintenance 1-23...
Page 52: Drive Belt Deflection
Install drive support arm and sprocket cover. Axle Apply LOCTITE THREADLOCKER 272 (red) to (metric) drive support screws. Tighten screws to 20-25 ft-lbs (27-34 Nm). Figure 1-24. Rear Axle Adjuster Tighten drive support nut to 35 ft-lbs (40-47 Nm). 1-24 2002 Buell S3T: Maintenance...
Page 53 Tighten locknut flush against adjusting nut. Adjusting Tighten axle nut (metric) to 66-73 ft-lbs (90-99 Nm). Verify that belt deﬂection is correct. Figure 1-26. Axle Adjuster Bolt, Right Side Shown 2002 Buell S3T: Maintenance 1-25...
Page 54: Drive Belt And Sprocket
If scribe or knife points digs in and leaves a visible mark, it is cutting the bare aluminum. A knife point will not penetrate the chrome plating. Replace rear sprocket if major tooth damage or loss of chrome exists. 1-26 2002 Buell S3T: Maintenance...
Page 55 OK to Run, but monitor condition Replace Belt #7 Stone Damage #8 Bevel Wear (Outboard Edge Only) Replace Belt if damage is on edge OK to Run, but monitor condition Figure 1-27. Drive Belt Wear Patterns 2002 Buell S3T: Maintenance 1-27...
Page 56: Primary Chain
Replace parts as necessary. See Section Adjusting Screw Figure 1-30. Loosen locknut (1). Turn adjusting screw (2): Clockwise (inward) to reduce freeplay. Counterclockwise (outward) to increase freeplay. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Figure 1-30. Primary Chain Adjustment 1-28 2002 Buell S3T: Maintenance...
Page 57: Preload Adjustment
Hold adjusting nut in place and tighten locknut to 65-72 ft-lbs (88-98 Nm) with crow’s foot set at 90 degrees to the torque wrench. Wipe excess grease off of shock absorber. 2002 Buell S3T: Maintenance 1-29...
Page 58: Suspension Damping Adjustments
Table 1-10. Recommended Damping Settings SOLO SOLO SOLO SETTINGS 2-UP (STD) (FIRM) (SOFT) Front Rebound Front Com- 1.75 1.25 1.25 pression b0558xox Compression Rear Rebound Adjuster Rear Com- 0.25 pression Figure 1-34. Front Fork Adjusters 1-30 2002 Buell S3T: Maintenance...
Page 59: Front Fork
Fork Oil TYPE E FORK OIL (Part No. HD-99884-80) Standard Capacity 15.36 ounces 450 cc Standard Oil Level 3.15 in. 80 mm Maximum Oil Level 2.36 in. 60 mm Minimum Oil Level 4.333 in. 110 mm 2002 Buell S3T: Maintenance 1-31...
Page 60: Steering Head Bearings
Lower Triple Clamp Tighten both lower triple clamp pinch screws (7) to 18-20 Figure 1-39. Steering Head Assembly ft-lbs (24-27 Nm). Tighten small pinch screw (8) on upper triple clamp to 10-12 ft-lbs (14-16 Nm). 1-32 2002 Buell S3T: Maintenance...
Page 61: Spark Plugs
Install and tighten to 11-18 ft- lbs (15-24 Nm). Connect spark plug cables. Longer cable attaches to rear cylinder spark plug. Verify that cables are securely connected to coil and spark plugs. 2002 Buell S3T: Maintenance 1-33...
Page 62: Air Cleaner
Place cover (3) over backplate assem- bly. Install both rear screws and nylon washers (1). Install both front screws and nylon washers (2). Install bolt and washer to fasten right fairing lower to bracket on swingarm/drive support. 1-34 2002 Buell S3T: Maintenance...
Page 63: Ignition Timing
Attach male gray connector on BREAKOUT BOX to wiring harness. Connect red (+) lead on voltmeter to Pin 3 on gray side of BREAKOUT BOX. Connect black (-) lead on voltmeter to Pin 8 on gray side of BREAKOUT BOX. 2002 Buell S3T: Maintenance 1-35...
Page 64 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 10. Install seat and tail section. See 2.33 TAIL SECTION. 1-36 2002 Buell S3T: Maintenance...
Page 65: Handlebars
Check steering motion range to both fork stops. Handle- Figure 1-50. Adjusting Handlebars bars should not make contact with the front forks, fuel tank or fairing. If handlebar needs further adjustment, repeat adjust- ment beginning with Step 1. 2002 Buell S3T: Maintenance 1-37...
Page 66: Throttle Cables
11. Install air cleaner assembly. See 4.41 AIR CLEANER. IDLE ADJUSTMENT Check idle adjustment: ● Before every ride. ● At every scheduled service interval. Regular idle speed is 850-1050 RPM. Set idle speed using idle adjuster and tachometer. 1-38 2002 Buell S3T: Maintenance...
Page 67: Headlamp
For Horizontal Adjustment: Figure 1-55. Use a nut driver on the right side headlamp mounting stud clockwise to aim beam to the right or turn the stud counterclockwise to aim beam to the left. 2002 Buell S3T: Maintenance 1-39...
Page 68: Storage
Improper clutch disen- gagement while vehicle is in motion may cause an acci- This work should be performed by your local Buell dealer fol- dent which could result in death or serious injury. lowing Service Manual procedures.
Page 69: Troubleshooting
O2, IAT or ET sensors damaged or malfunctioning. See Insufﬁcient oil supply or oil not circulating. dealer. Ignition coil not functioning. Leaking valves. Engine oil too heavy (winter operation). Heavy carbon deposit. Water or dirt in fuel system/clogged fuel ﬁlter/injector. Ignition timing retarded. 2002 Buell S3T: Maintenance 1-41...
Page 70: Electrical System
Clutch controls improperly adjusted. Engine ground wire loose or broken. Clutch plates excessively warped. Loose or broken wires in charging circuit. Chatters Stator not functioning. Rotor not functioning. Friction or steel plates worn, warped or dragging. 1-42 2002 Buell S3T: Maintenance...
Page 71 FORK STEM AND BRACKET ASSEMBLY. 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 handling. 2002 Buell S3T: Maintenance 1-43...
Page 72 HOME NOTES 1-44 2002 Buell S3T: Maintenance...
Page 73 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 75: Chassis
Gross Axle Weight Ratings (GAWR) are given on an information decal located on the left front down tube. BRAKE SERVICE WEAR LIMITS Minimum Rotor Thickness 0.18 (Front and Rear) Minimum Brake Pad Thickness 0.04 (Front and Rear) 2002 Buell S3T: Chassis...
Page 76 54-61 Nm metric Fuel Tank Mounting Bolt 18-23 ft-lbs, 24-31 Nm, Special procedure. then wait 5 then wait 5 minutes and minutes and retighten. retighten. Handlebar Clamp Screw 10-12 ft-lbs 14-16 Nm tighten front screws ﬁrst 2002 Buell S3T: Chassis...
Page 77 LOCTITE THREADLOCKER 272 (red) 20-25 ft-lbs 27-34 Nm Screw Switchgear Housing Screws, metric 25-33 in-lbs 3-4 Nm (left side) Switchgear Housing Screws, metric 12-17 in-lbs 1-2 Nm (right side) Valve Stem Nut 42-44 in-lbs 4.7-5.0 Nm 2002 Buell S3T: Chassis...
Page 78: Tire Specifications
& POSITION RIM SIZE HOLE DIAMETER RADIAL TIRE SIZE 17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17 D205F 17 in. – Rear MT 5.5 x 17.0 DOT 0.33 in. 170/60 ZR17 D205 2002 Buell S3T: Chassis...
Page 79: Vehicle Identification Number
An abbreviated V.I.N. is stamped on the front left side of the crankcase. NOTE Figure 2-2. Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle. Figure 2-1. Abbreviated V.I.N. Location Manufacturer: Buell Motorcycle Company FS = S3T...
Page 80: Wheels
Correct adjustment and replace pitted or worn bearings. See 1.16 STEER- ING HEAD BEARINGS. Damper tubes. Check for leaks. See 2.16 FRONT FORK. Shock absorbers. Check damping action and mounts. See 1.14 SUSPENSION DAMPING ADJUSTMENTS. Swingarm bearings. Check for looseness. See 2.19 SWINGARM. 2002 Buell S3T: Chassis...
Page 81 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 (130 km/h).
Page 82: Front Wheel
Inspect all parts for damage or excessive wear. Inspect brake rotor. Measure rotor thickness. Replace if less than ser- vice wear limit. See 1.7 BRAKE PADS AND ROTORS. Check rotor surface. Replace if warped or badly scored. 2002 Buell S3T: Chassis...
Page 83 13-15 ft-lbs (18-20 Nm). Push axle through left fork leg. Install front brake caliper. See 2.11 FRONT BRAKE Compress the front suspension to make sure it is free CALIPER. and not binding. 2002 Buell S3T: Chassis...
Page 84: Rear Wheel
Measure rotor thickness. Replace if less than ser- vice wear limit. See 1.7 BRAKE PADS AND ROTORS. Check rotor surface. Replace if warped or badly scored. Axle Rear Brake Caliper Mount Swingarm Washer Figure 2-7. Rear Wheel With Axle Carrier (Left Side) 2-10 2002 Buell S3T: Chassis...
Page 85 REAR BRAKE CALIPER. Check for proper belt tension and wheel alignment. See 1.10 DRIVE BELT DEFLECTION. Tighten rear axle nut (14) (metric) to 66-73 ft-lbs (90- 99 Nm). Install saddlebags (if equipped). See 2.37 SADDLE- BAGS. 2002 Buell S3T: Chassis 2-11...
Page 86: Checking Cast Rim Runout
Wheel Truing and Balancing RUNOUT RUNOUT Stand (Part No. HD-99500-80) Cast 0.040 in. 0.030 in. (1.02 mm) (0.76 mm) Aluminum P/M 0.020 in. 0.020 in. (0.51 mm) (0.51 mm) Gauge rod Figure 2-10. Checking Cast Rim Radial Runout 2-12 2002 Buell S3T: Chassis...
Page 87: Tires
WARNING WARNING A bead breaker Dunlop front and rear tires for Buell motorcycles are not machine simplifies tire the same. They are not interchangeable. Use front tire ONLY for a front tire. DO NOT put a rear tire on the front Figure 2-11.
Page 88 (2.03 mm). If runout is more than 0.080 in. (2.03 mm), remove tire from rim. Check rim bead side runout. See 2.7 CHECKING CAST RUNOUT. Replace rims not meeting speciﬁcations. Install tire and check again for tire tread lateral runout. 2-14 2002 Buell S3T: Chassis...
Page 89: 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 S3T: Chassis 2-15...
Page 90: Brakes
Spilling ing or bleeding system. To prevent death or serious brake ﬂuid on switches may render them inoperative. injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed technician. 2-16...
Page 91 Replace pads. brake pads. Brake pads drag on rotor – Cup in master cylinder not uncovering Inspect master cylinder. will not retract. relief port. Rear brake pedal linkage out of Adjust linkage. adjustment. 2002 Buell S3T: Chassis 2-17...
Page 92: Front Brake Master Cylinder
Figure 2-21. Compress piston (2) and remove boot (1). Figure 2-18. Front Master Cylinder Depress piston assembly and remove internal snap ring (3). Discard snap ring. Figure 2-22. Remove piston assembly (1-4) from front master cylinder. 2-18 2002 Buell S3T: Chassis...
Page 93 Install front brake switch. Attach front brake switch with screw, washer and lockwasher (1). Tighten to 7-13 in-lbs (1-2 Nm). Test switch action. Tang (2) on switch must release when hand lever (3) is moved. 2002 Buell S3T: Chassis 2-19...
Page 94 Failure to have proper brake lamp opera- tion could result in death or serious injury. Turn ignition key switch to IGN. Apply brake hand lever to test brake lamp operation. Turn ignition key switch to OFF. 2-20 2002 Buell S3T: Chassis...
Page 95: Front Brake Caliper
REMOVER (Part No. B-42887) without adaptor to pull the six pistons from caliper bores. Figure 2-28. Pry O-rings (6) out of their respective grooves on each side of caliper. Discard O-rings. Check bleeder valve (4) (metric). Remove and replace if damaged. 2002 Buell S3T: Chassis 2-21...
Page 96 Install brake pads. Install a new bleeder valve (4) (metric) if necessary. Figure 2-29. Insert brake pads from behind. Tighten to 3-5 ft-lbs (4-7 Nm). Figure 2-26. Install pad spring (2) with opening at top as shown. 2-22 2002 Buell S3T: Chassis...
Page 97 WARNING Check for proper brake lamp operation before riding motorcycle (see Step 10). Visibility is a major concern for motorcyclists. Failure to have proper brake lamp opera- tion could result in death or serious injury. 2002 Buell S3T: Chassis 2-23...
Page 98: Front Brake Line
Figure 2-31. Front Brake Line Connect brake line to caliper using two new banjo wash- ers and banjo bolt. Loosely install bolt into caliper. Tighten clamp screw on lower triple clamp to 30-35 in-lbs (3-4 Nm) 2-24 2002 Buell S3T: Chassis...
Page 99: Rear Brake Master Cylinder
13. Remote Reservoir away from master cylinder body (1). Figure 2-33. Rear Master Cylinder Assembly Depress rod assembly (3) and remove internal snap ring (2). Discard snap ring. Remove piston assembly (4) from master cylinder body. 2002 Buell S3T: Chassis 2-25...
Page 100 Figure 2-33. Connect brake line (3) to master cylin- der (4) with two new banjo washers (2) and banjo bolt (1) (metric). Tighten to 16-20 ft-lbs (22-27 Nm). 2-26 2002 Buell S3T: Chassis...
Page 101 Turn ignition key switch to IGN. Apply rear brake pedal to test brake lamp operation. Turn ignition key switch to LOCK. Master Cylinder Body Snap Ring Rod Assembly Piston Assembly Figure 2-37. Master Cylinder Internals 2002 Buell S3T: Chassis 2-27...
Page 102: Rear Brake Caliper
Always replace brake pads in complete appear damaged or worn. Do not hone caliper piston sets for correct brake operation. Never replace just one bore. brake pad. Failure to comply could result in death or seri- ous injury. 2-28 2002 Buell S3T: Chassis...
Page 103 Avoid making hard stops for the ﬁrst 100 miles (160 km) to washers (3) and banjo bolt (2) (metric). Tighten to 16- allow new brake pads to “wear in” properly with the brake 20 ft-lbs (22-27 Nm). rotor. 2002 Buell S3T: Chassis 2-29...
Page 104: Rear Brake Line And Switch
Tighten to 10-12 ft-lbs (14- 16 Nm). Place brake line inside wire guide (5) closest to master cylinder. Figure 2-44. Attach the wireform under the oil tank with bolt and washer. 2-30 2002 Buell S3T: Chassis...
Page 105 Step 2 10. Turn ignition key switch to IGN. Apply rear brake pedal to test brake lamp operation. Turn ignition key switch to LOCK. Step 3 Figure 2-45. Wireform Installation 2002 Buell S3T: Chassis 2-31...
Page 106: Front Fork
Improperly operating forks may lead to a loss of control and death or serious injury. Remove the dust seal (13) and the stopper ring (12) from the outer tube (8). Pull the slide pipe (17) out of the outer tube (8). 2-32 2002 Buell S3T: Chassis...
Page 107 11. Oil Seal 12. Stopper Ring 13. Dust Seal 14. Damper Assembly 15. Centering Plate 16. Slide Bushing 17. Slide Pipe 18. Special Washer 19. Center Bolt 20. Mounting Bolt b0652x2x Figure 2-48. Front Fork Assembly 2002 Buell S3T: Chassis 2-33...
Page 108 11. While supporting the fork, pour one-half of the recom- mended amount of fork oil, 8 oz. (225 cc), into the fork pipe. 12. Pump the piston rod and leg slowly at least 10 times, about 6 in. (150 mm) strokes. 2-34 2002 Buell S3T: Chassis...
Page 109 21. Set rebound and compression adjusters to factory posi- tions. See 1.14 SUSPENSION DAMPING ADJUST- b0666x2x MENTS. Oil Level: Maximum: )2.36 in. (60.0 mm) Minimum: 4.33 in. (110.0 mm Figure 2-53. Oil Level Measurement 7097 Thin Taper at Top Figure 2-54. Spring Installation 2002 Buell S3T: Chassis 2-35...
Page 110 Install front wheel. See 2.5 FRONT WHEEL. Large Upper Triple Clamp Screw (2) Install front brake caliper. See 2.11 FRONT BRAKE CALIPER. Figure 2-55. Front Fork Adjust front forks to rider preferences. See 1.15 FRONT FORK. 2-36 2002 Buell S3T: Chassis...
Page 111: Fork Stem And Bracket Assembly
Insert lower triple clamp (6) through the steering head. Install the upper bearing (4) with small end down and dust shield (3) onto fork stem. Apply LOCTITE ANTI-SEIZE to fork stem bolt (1). Loosely install upper triple clamp (2) using fork stem bolt. 2002 Buell S3T: Chassis 2-37...
Page 112: Steering Head Lock
Turn handlebars all the way to the left. Insert ignition key in lock. Turn key clockwise while pushing in. Remove key and verify that steering head is locked. Unlock steering head by inserting key and turning 2-38 2002 Buell S3T: Chassis...
Page 113: Swingarm
Detach feed line from bottom of oil tank. 10. Detach rear brake pedal from master cylinder pushrod. 11. Remove left side rider footrest and shifter lever. Drain Hose Clamp Drain Plug Frame Tube b0451xox Figure 2-61. Oil Tank Drain, Typical 2002 Buell S3T: Chassis 2-39...
Page 114 Tighten rod to an initial torque of 11-12 ft-lbs (15-16 Nm). Check swingarm preload using a scale as shown in Fig- ure 2-65. Preload should be 3.0-3.75 lbs (1.36-1.70 kg). If preload does not meet speciﬁcations, tighten or loosen threaded rod and recheck. 2-40 2002 Buell S3T: Chassis...
Page 115 15. Attach left side rider footrest and shifter lever. Apply LOCTITE THREADLOCKER 272 (red) to bolt. Tighten to 23-25 ft-lbs (31-34 Nm). 16. Install rear wheel. See 2.6 REAR WHEEL. 3.0-3.75 lbs (1.36-1.70 kg) Figure 2-65. Checking Preload 2002 Buell S3T: Chassis 2-41...
Page 116 24. Check rear brake operation. 6852 Axle Adjuster Bolt Locknut Adjusting Nut Figure 2-68. Axle Adjuster Bolt, Right Side Shown 2-42 2002 Buell S3T: Chassis...
Page 117: Rear Isolators
Loosen left side isolator bolt from swing rails arm bearing adjusting bolt. Do not remove. 10. See Figure 2-71. Remove right side isolator bolt and washer from swingarm bearing adjustment bolt. Figure 2-70. Floor Hoist 2002 Buell S3T: Chassis 2-43...
Page 118 Failure to comply may result in frame distortion or damage. Turn nut on tool clockwise to expand frame from mount block. Nut will stop when limit of travel is reached. Figure 2-73. Measuring Roll Pin Protrusion 2-44 2002 Buell S3T: Chassis...
Page 119 Tighten to 48-72 in-lbs (5-9 Nm). Apply LOCTITE THREADLOCKER 272 (red) to swingarm/drive support mounting screws and install. Tighten screws to 20-25 ft-lbs (27-34 Nm). Install locknut and washer. Tighten to 30-35 ft-lbs (41-47 Nm). 2002 Buell S3T: Chassis 2-45...
Page 120: Rear Shock Absorber
11. Remove lifting straps and install seat. See 2.35 SEAT. 12. Check rear shock preload. See 1.13 PRELOAD ADJUSTMENT. 2-46 2002 Buell S3T: Chassis...
Page 121 Reservoir Mount Block Rear Reservoir Clamp Nylon Locknut (2) Washers Front Reservoir Clamp Washers (3) Metal Locknut (2) 30-33 ft-lbs (41-45 Nm) Front Shock Mount 40-45 ft-lbs (54-61 Nm) Figure 2-76. Rear Shock Absorber 2002 Buell S3T: Chassis 2-47...
Page 122: Suspension Theory
NOTE Evaluating and changing the rebound and compression damping is a very subjective process. Many variables affect motorcycle handling under different circumstances. Approach all changes carefully. Consult Table 2-10. Figure 2-79. Front Fork Adjusters 2-48 2002 Buell S3T: Chassis...
Page 123: Suspension Adjustments
(STD) (FIRM) (SOFT) Make this adjustment before the motorcycle is ridden any dis- Front Rebound tance. Your Buell dealer can assist you if necessary. Front Compression 1.75 1.25 1.25 Rear Rebound...
Page 124 Not absorbing bumps. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings. Lack of tire feedback. Increase compression damping. Tire slides. Decrease compression damping. 2-50 2002 Buell S3T: Chassis...
Page 125 FRONT FORK REAR SHOCK REAR SHOCK DATE RESULTS REBOUND COMPRESSION REBOUND COMPRESSION Max damping Max damping Max damping Max damping Factory recommended minus 0.5 turn minus 1.75 turns minus 1 turn minus 2.5 turns settings. 2002 Buell S3T: Chassis 2-51...
Page 126: Throttle Control
Install air cleaner assembly. See 4.41 AIR CLEANER. Rear Housing Install the right fairing lower. See 2.38 FAIRING LOW- 10. Locating Pin ERS. Figure 2-82. Cable Connections Throttle Cable Clamps Screw Arrow (Up) Figure 2-80. Throttle Cable Clamps 2-52 2002 Buell S3T: Chassis...
Page 127: Clutch Control
Outer Ramp Ball (3) O-Ring Cable End Fitting 10. Clutch Cable End 11. Primary Cover 12. Clutch Adjusting Screw Assembly 13. Retaining Ring 14. Quad Ring 15. Inner Ramp 16. Coupling Figure 2-83. Clutch Release Mechanism 2002 Buell S3T: Chassis 2-53...
Page 128 Figure 2-85. Route cable down left side of bike, through clamp, along primary chaincase to clutch. With clutch cable lower section connected to primary cover, adjust clutch. See CLUTCH. 2-54 2002 Buell S3T: Chassis...
Page 129: Handlebars
Wipe off excess adhesive with a rag. Install front brake master cylinder. See 2.10 FRONT BRAKE MASTER CYLINDER. Check steering motion range to both fork stops. See 1.16 STEERING HEAD BEARINGS. 2002 Buell S3T: Chassis 2-55...
Page 130: Exhaust System
Slide exhaust header from behind frame. Figure 2-93. Remove exhaust header clamps (22), Jack exhaust clamp retaining rings (23) and exhaust port gas- kets (24) from exhaust header. Figure 2-90. Supporting Motorcycle with Jack 2-56 2002 Buell S3T: Chassis...
Page 131 Mount Bracket Washer (2) Spacer Washers (2) Grade 8 Bolt 22-24 ft-lbs Mount Metal (30-33 Nm) Tabs Locknuts (2) 20-22 ft-lbs (27-30 Nm) Muffler Metal Locknut Voltage Regulator Mounting Bracket Voltage Regulator Figure 2-91. Exhaust System 2002 Buell S3T: Chassis 2-57...
Page 132 (1). Figure 2-92. Slide exhaust header under frame by Tighten mufﬂer clamp to 40-45 ft-lbs (54-61 Nm). positioning as shown, threading oxygen sensor wire under frame. Install right fairing lower. See 2.38 FAIRING LOWERS. 2-58 2002 Buell S3T: Chassis...
Page 133: Footrests
Install pin (11) through spring (12), mount (5) and footrest (4). Install washer (13) and retaining ring (14) to pin. Make sure retaining ring engages groove on pin. Adjust shift lever and brake pedal for smooth operation. 2002 Buell S3T: Chassis 2-59...
Page 134: Sprocket Cover
Tighten screws to 20-25 ft-lbs (27-34 Nm). Figure 2-96. Place fairing lower bracket on stud. Fasten fairing lower to bracket using screw. Bracket Screw and Wellnut Right Fairing Lower Figure 2-96. Fairing Lower Mount 2-60 2002 Buell S3T: Chassis...
Page 135: Stone Guard
Position stone guard (4) with wellnuts (5) and lower belt guard (3) on swing arm. Secure with two screws (1) and washers (2). Screw (2) Washer (2) Lower Belt Guard Stone Guard Wellnut (2) Figure 2-97. Stone Guard 2002 Buell S3T: Chassis 2-61...
Page 136: Front Fender
ﬁts between fork leg and back of fender. Tighten to Figure 2-98. Front Fender 10-15 in-lbs (1-2 Nm). Tighten upper mounting screws (1, 5) to 20-25 in-lbs (2-3 Nm). Install front wheel. See 2.5 FRONT WHEEL. 2-62 2002 Buell S3T: Chassis...
Page 137: Rear Fender
Install screw (5) and washer (6) into wellnut (7). Fender Wellnut (2) Install screws (1) and washers (2) into wellnuts (4). Screw Washer Wellnut Screw Washer Figure 2-99. Rear Fender 6883 Figure 2-100. Rear Fender With Brake Hose 2002 Buell S3T: Chassis 2-63...
Page 138: Tail Section
Lift and remove glove box. Slide wiring harness through hole in side. Figure 2-102. Glove Box Figure 2-103. You may remove bolts, washers and nuts (2) to detach rear saddlebag support bracket (3) from turn signal support bracket (1). 2-64 2002 Buell S3T: Chassis...
Page 139 Place glove box (2) on license plate holder. Secure with two bolts, washers and nuts (1). Thread tail lamp wiring (4) through hole in glove box. Install tail lamp mount. Attach tail lamp/brake light con- nections. See 7.2 TAIL LAMP. 2002 Buell S3T: Chassis 2-65...
Page 140: Front Fairing
Remove two locknuts (1), washers (2) Figure 2-105. Front Fairing and bolts (3) to detach front fairing mount from steering head. b0425x2x Locknut (2) Washer (2) Bolt (2) Front Fairing Mount Figure 2-106. Front Fairing Mount 2-66 2002 Buell S3T: Chassis...
Page 141 7.3 TURN SIGNALS. Tighten both nuts (metric) on mirrors to 7-10 in-lbs (0.8- 1.1 Nm). Install both fairing bags (4). Right Turn Signal Wires Left Turn Signal Wires Cable Straps b0469x2x Figure 2-108. Cable Straps 2002 Buell S3T: Chassis 2-67...
Page 142: Seat
● Figure 2-112. Metal tabs on tail section are helmet brackets (1). Place helmet D-ring under tab. Install and Figure 2-111. Seat Release lock seat to secure helmet for storage while motorcycle is stationary. 2-68 2002 Buell S3T: Chassis...
Page 143 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat and test as described. 2002 Buell S3T: Chassis 2-69...
Page 144: Side Stand
(8) and retaining clip (7). Do not crush side stand switch during installation. Connect spring (6) to side stand and spring pin (5). Figure 2-117. Side Stand Dragger Wear Limit Remove REAR WHEEL STAND. 2-70 2002 Buell S3T: Chassis...
Page 145: Saddlebags
Saddlebag support brackets are not “grab handles” for passenger. Using support bracket as a passenger grab handle could result in death or serious injury. Pull fastener handle open. Turn handle 1/4 turn to release saddlebag from support bracket. 2002 Buell S3T: Chassis 2-71...
Page 146 Turn bumper (2) counterclockwise until it contacts saddlebag (3). Turn bumper one additional full turn counterclock- wise. Tighten jamnut (1) against rear saddlebag support bracket. Slide rubber boot over bumper assembly. Jamnut Bumper Saddlebag b0438x2x Figure 2-121. Saddlebag Alignment 2-72 2002 Buell S3T: Chassis...
Page 147: Fairing Lowers
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.35 SEAT. 2002 Buell S3T: Chassis 2-73...
Page 148 HOME NOTES 2-74 2002 Buell S3T: Chassis...
Page 149 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 151: Specifications
2.105 in. (min) 53.467 mm (min) Intake 1.751-1.848 in. 72-92 lbs 33-42 kg (closed) 1.286-1.383 in. 183-207 lbs 83-94 kg (open) Exhaust 1.751-1.848 in. 72-92 lbs 33-42 kg (closed) 1.332-1.429 in. 171-195 lbs 78-88 kg (open) 2002 Buell S3T: Engine...
Page 152 3.5050 in. 89.0270 mm 0.010 OS 3.507 in. 89.078 mm 3.5100 in. 89.1540 mm OS=over size 0.020 OS 3.517 in. 89.332 mm 3.5200 in. 89.4080 mm 0.030 OS 3.527 in. 89.586 mm 3.5300 in. 89.6620 mm 2002 Buell S3T: Engine...
Page 153 Outer race diameter in 1.5646-1.5652 in. 39.7408-39.7561 mm 1.5672 in. (max) 39.8069 mm (max) right crankcase Bearing running clearance 0.00012-0.00088 in. 0.00305-0.02235 mm Fit in cover bushing 0.0023-0.0043 in. 0.0584-0.1092 mm 0.0050 in. 0.1270 mm (loose) 2002 Buell S3T: Engine...
Page 154 15-18 Nm Rocker Box to Head Bolts 18-22 ft-lbs 24-30 Nm Swingarm Mount Block 68-75 ft-lbs 92-102 Nm Bolts (Lower) Swingarm Mount Block 41-45 ft-lbs 56-61 Nm Bolts (Upper) Tie Bar Bolts 30-33 ft-lbs 41-45 Nm 2002 Buell S3T: Engine...
Page 155: Engine
Your motorcycle will run normally using this type of gas. verted to circular motion in the crankcase. The multi-piece Buell recommends you use it when possible, as an aid to crankshaft consists of a crank pin mounted between two cleaner air in our environment.
Page 156 Valve trouble Compression low on ﬁrst stroke; does not build up much on follow- ing strokes; does not improve con- siderably with the addition of oil. Head gasket leak Same reaction as valve trouble. 2002 Buell S3T: Engine...
Page 157: Diagnosing Smoking Engine Or High Oil Consumption
Repeat procedure on rear cylinder. CAUTION After completing the compression test(s), make sure that the throttle plate is in the closed position before starting engine. Engine will start at an extremely high RPM if throttle plate is left open. 2002 Buell S3T: Engine...
Page 158: Stripping Motorcycle For Engine Repair
Raise hoist until straps tighten. 16. See Figure 3-3. Remove engine ground strap (1) from swingarm mount block. Detach clutch cable from handlebar lever. 17. Detach remaining tie bars from frame. 2002 Buell S3T: Engine...
Page 159 (3, 4), washers and locknuts. Clutch Cable Clamp Washer Locknut b0251x3x Front Isolator bolt Washer Front Isolator D-Washer 10. Nut 11. Front Upper Tie Bar Crating Strap Figure 3-2. Supporting the Engine Figure 3-4. Front Tie Bar Assembly 2002 Buell S3T: Engine...
Page 160: Installing The Engine
ﬂoor hoist, lift motorcycle by the frame and remove the wooden cradle from underneath the crankcase. 17. Install rear shock. See 2.21 REAR SHOCK ABSORBER. Remove ﬂoor hoist straps. 18. Install rear wheel and attach drive belt. See 2.6 REAR WHEEL. 3-10 2002 Buell S3T: Engine...
Page 161 1.10 DRIVE BELT DEFLECTION. Adjust rear shock spring preload. See 1.13 PRE- LOAD ADJUSTMENT. Adjust clutch lever. See CLUTCH. Check rear brake pedal height. See 1.5 BRAKES. 11. Check all electrical components for proper operation. 2002 Buell S3T: Engine 3-11...
Page 162: Cylinder Head
Distortion to the head, cylinder and crankcase studs may result if head screws are not loosened (or tightened) gradually in the sequence shown in Figure 3-7. Figure 3-7. Loosen each head screw 1/8-turn follow- ing the sequence shown. 3-12 2002 Buell S3T: Engine...
Page 163 Remove both push rod covers (7) and hydraulic lifters (6). See 3.15 HYDRAULIC LIFTERS. 14. Repeat the above procedure for the other cylinder head. b0390x3x Figure 3-8. Front Isolator Mount (4th Tie Bar Not Shown) 2002 Buell S3T: Engine 3-13...
Page 164 18. Cylinder Head Inner Valve Spring (2) 12. Cylinder Stud (4) 19. Cylinder Outer Valve Spring (2) 13. Base Gasket 20. Piston Valve Keeper (4) 14. O-Ring (2) Figure 3-9. Cylinder Head, Cylinder and Piston 3-14 2002 Buell S3T: Engine...
Page 165 Seal (2) Retainer (2) O-Ring (2) Figure 3-10. Valve Spring Compressor Screw (2) (Part No. HD-34736B) Push Rod (2) 10. Washer (2) 11. Locating Pin (2) Figure 3-11. Middle Valve Train Components (Quantities per Engine Cylinder) 2002 Buell S3T: Engine 3-15...
Page 166 LIMITS. Repair or replace parts exceeding limits. Assemble rocker arms and rocker arm shafts into lower Figure 3-15. Measuring Rocker Arm Bushing rocker cover. Inner Diameter Check end play of rocker arm with feeler gauge. 3-16 2002 Buell S3T: Engine...
Page 167 Using remaining old bushing as a pilot, line ream new bushing with ROCKER ARM BUSHING REAMER (Part HD-94804-57). Repeat for other end of rocker arm. 2002 Buell S3T: Engine 3-17...
Page 168 60°. NOTE The hone is not intended to remove material. Figure 3-20. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (1) (Part No. HD-34751) and hot soapy water. 3-18 2002 Buell S3T: Engine...
Page 169 Wipe valve seats and valve faces clean. Measure valve stem protrusion. If valve stem protrudes more than 2.031 in. (51.587 mm), replace valve seat or cylinder head. If valve stem protrusion is acceptable, valves and seats are ready for lapping. 2002 Buell S3T: Engine 3-19...
Page 170 Figure 3-23. Measuring Valve Stem Protrusion seated. If lapped ﬁnish is not complete, further lapping (or grinding and lapping) is necessary. 5693 Valve Lapping Tool (Part No. HD-96550-36A) Cylinder Head Holding Fixture (Part No. HD-39786) Figure 3-24. Lapping Valves 3-20 2002 Buell S3T: Engine...
Page 171 Clean residual loctite from threads in engine with a suitable nonﬂammable solvent and dry with com- pressed air. Apply LOCTITE THREADLOCKER 271 (red) to threads of new front isolator mount bolts. Figure 3-26. Valve Guide Seal Protector Sleeve 2002 Buell S3T: Engine 3-21...
Page 172 (lowest position) of the cam. 13. Apply a liberal amount of engine oil to lifter assembly (especially roller needles) for smooth initial operation. 3-22 2002 Buell S3T: Engine...
Page 173 Install upper rocker cover (4) using screws with washers (1) and new ﬁber seals (2). Tighten screws Figure 3-28. Lower Rocker Box Fasteners to 10-14 ft-lbs (14-19 Nm). 21. Install the other cylinder using the same procedure. 2002 Buell S3T: Engine 3-23...
Page 174: Cylinder And Piston
Since the piston pin is a loose ﬁt in the piston, the pin will easily slide out. The pins have tapered ends to help seat the round retaining rings. See Figure 3-30. 1203cc piston pins are stamped with a V-groove at one end. 3-24 2002 Buell S3T: Engine...
Page 175 Lay a straightedge across the surface. Try to insert a feeler gauge between the straight- edge and the gasket surface. If cylinder base gasket surface is not ﬂat within 0.008 in. (0.203 mm), replace cylinder and piston. 2002 Buell S3T: Engine 3-25...
Page 176 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) 3-26 2002 Buell S3T: Engine...
Page 177: Boring And Honing Cylinder
Check end gap with thickness gauge. See 3.1 SPECIFICATIONS for tolerance. NOTE SERVICE WEAR LIMITS for end gap dimensions. Do not ﬁle rings to obtain proper gap. Figure 3-34. Measuring Ring End Gap 2002 Buell S3T: Engine 3-27...
Page 178 If the ring grooves are clean and the side play is still not cor- rect, replace the rings, the piston or both. Piston REAR Figure 3-36. Ring End Gap Position 2785a Figure 3-37. Measuring Ring Clearance in Groove 3-28 2002 Buell S3T: Engine...
Page 179 Driver Installing bent connecting rods will damage cylinder and Washer piston beyond repair. Bolt Figure 3-39. Piston Pin Bushing Tool Assembly for Bushing Removal 2002 Buell S3T: Engine 3-29...
Page 180 12. Remove PISTON RING COMPRESSOR. Figure 3-42. Compressing Piston Rings 13. Assemble cylinder head. See 3.5 CYLINDER HEAD. 14. Install cylinder head. See 3.5 CYLINDER HEAD. 15. Install assembled engine. See 3.4 INSTALLING THE ENGINE. 3-30 2002 Buell S3T: Engine...
Page 181: Lubrication System
In winter the oil change interval should be shorter than nor- mal. The colder the weather, the shorter the recommended oil change interval. A vehicle used only for short runs in cold weather must have the engine oil drained frequently. 2002 Buell S3T: Engine 3-31...
Page 182: Oil Hose Routing
ﬁtting (3) on the gearcase cover (4). b0248a3x b0344x3x Vent Hose Clamp Feed Hose Return Hose Elbow Fitting Drain Hose T-Fitting Gearcase Cover Vent Hose Figure 3-45. Vent Hose Connection (Typical) Figure 3-43. Oil Tank Hoses 3-32 2002 Buell S3T: Engine...
Page 183: Oil Tank
If seat is loose, it could shift during vehicle operation and startle the rider, which could result in death or serious injury. Install tail section, fuel tank and seat. See 2.33 TAIL SECTION. 2002 Buell S3T: Engine 3-33...
Page 184: Oil Pressure Indicator Switch
Burned-out signal bulb. is turned on psi (69-117 kN/m ). At idle speed (950-1050 RPM), oil pres- ● Dead battery (see NOTE above). (prior to oper- sure will vary from 7-12 psi (48-83 kN/m ating engine). 3-34 2002 Buell S3T: Engine...
Page 185: Crankcase Breathing System
(4). Hoses leading from the air cleaner bolts vent the air to the air cleaner’s snorkel. Push Rod Cover (2) Oil Drain Hole Umbrella Valve Breather Bolt Figure 3-49. Crankcase Breathing System, Typical Cylinder 2002 Buell S3T: Engine 3-35...
Page 186: Oiling System (Color Foldout)
Oil is transferred to the teeth of all the cam gears Oil also enters an intersecting passage in the gearcase cover. Oil ﬂow is then routed to the crankshaft area. through the gear meshing action. 3-36 2002 Buell S3T: Engine...
Page 187: Oil Pump
Outer Gerotor between gerotor teeth Oil Inlet Oil Outlet Oil trapped between gerotor teeth Oil forced out Oil Inlet Oil Outlet Oil trapped between inner and outer gerotor teeth Outlet Figure 3-50. Principle of Gerotor Operation 2002 Buell S3T: Engine 3-37...
Page 188 12. Body Feed Hose Connection 13. Return Hose Elbow Connector Return Hose Connection 14. O-Ring Oil Filter Hose Connection 15. Thrust Washer Clamp 16. Retaining Ring Figure 3-51. Oil Pump Hardware Figure 3-52. Oil Pump 3-38 2002 Buell S3T: Engine...
Page 189 Operate at idle and allow about 2.0 ounces (0.06 liter) of engine oil to be forced through hose con- nection. Stop engine and tighten hose connection. 13. Check engine oil level. Add oil to correct level if needed. 1.4 ENGINE LUBRICATION SYSTEM. 2002 Buell S3T: Engine 3-39...
Page 190: Oil Filter Mount
Apply LOCTITE THREADLOCKER 243 (blue) to the ENGINE LUBRICATION SYSTEM. threads on that end of the ﬁlter adapter (1) which is installed into ﬁlter mount (4). Do not apply LOCTITE to adapter threads on ﬁlter element side. 3-40 2002 Buell S3T: Engine...
Page 191: Hydraulic Lifters
WEAR LIMIT of 0.026 in. (0.660 mm). Inside and outside micrometers used for measuring lifters and lifter guides must be calibrated to ensure accurate read- Soak lifters in clean engine oil. Keep covered until ings. assembly. 2002 Buell S3T: Engine 3-41...
Page 192 Insert screw (8) with washer (10) through hole in retainer (6). Thread screw (8) into tapped hole in crankcase. Tighten to 15-18 ft-lbs (20-24 Nm). Install push rods and rocker covers. See 3.5 CYLINDER HEAD. 3-42 2002 Buell S3T: Engine...
Page 193: Gearcase Cover And Cam Gears
15. Rear Intake Cam Gear Bushing Front Exhaust Cam Gear 10. Right Crankcase Half 16. Pinion Shaft Bushing Pinion Gear 11. Nut 17. Gearcase Cover Seal 12. Oil Pump Drive Gear Figure 3-59. Gearcase and Valve Train Components 2002 Buell S3T: Engine 3-43...
Page 194 See Table 3-9. Figure 3-61. Use a BUSHING AND BEARING PULLER (Part No. HD-95760-69A) to remove bushings Figure 3-61. Removing Bushing from gearcase cover and crankcase. 3-44 2002 Buell S3T: Engine...
Page 195 (7, 8 and 14) in its gearcase cover (17) bore so that bushing shoulder contacts cover boss. Orient each bushing so the oiling slot is at the 9 o’clock position within the gearcase cover bore. 2002 Buell S3T: Engine 3-45...
Page 196 Detach reamer from handle. Pull reamer out opposite side of crankcase half. Figure 3-63. Rear Intake Cam Gear Bushing Installed in Gearcase Cover Thoroughly clean right crankcase half, removing all metal chips/shavings. Blow out all oil passages using compressed air. 3-46 2002 Buell S3T: Engine...
Page 197 Separate gearcase cover from right crankcase half. Separate gearcase cover from right crankcase half. Inspect bushing for proper cam gear shaft ﬁt. Repeat line Inspect bushing for proper pinion shaft ﬁt. Repeat line reaming operation if necessary. reaming operation if necessary. 2002 Buell S3T: Engine 3-47...
Page 198 Keyway Figure 3-59. Install a new seal (6) and new dry Shaft Key gearcover gasket (9) on gearcase cover (17). Oil Pump Drive Gear Figure 3-68. Aligning Pinion Gear 3-48 2002 Buell S3T: Engine...
Page 199 4.30 CAM POSITION SENSOR AND ROTOR. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-71. Checking Cam Gear End Play b0337a3x Figure 3-69. Crankshaft Locking Tool (HD-43984) 2002 Buell S3T: Engine 3-49...
Page 200: Crankcase
0.005 in. (0.025-0.127 mm). Choose shim from PART Table 3-10. COLOR NUMBER NOTE 24647-87 Blue Use a thinner shim for less end play; use a thicker shim for more end play. 24650-87 24659-87 White/Grey 24660-87 Green 3-50 2002 Buell S3T: Engine...
Page 201 Upper Case Hex Socket Head Screw – 5/16-18 X 2-1/2 in. (4) Bottom Case T40 TORX Bolt – 5/16-18 X 3/4 in. (4) Mufﬂer Mount Bolt – 3/8-16 X 5-1/2 in. (2, with Washers and Locknuts) Figure 3-73. Crankcase Hardware (Typical) 2002 Buell S3T: Engine 3-51...
Page 202 Retaining Ring Fitting Left Crankcase Half **Gearshaft Bearing Bearing Cup Right Crankcase Half Bearing Bearing Race Retaining Ring *Shim Outer Bearing Sprocket Shaft Bearing Spacer Snap Bearing Ring b0804a3x Oil Seal Figure 3-75. Crankcase Assembly 3-52 2002 Buell S3T: Engine...
Page 203 Figure 3-76. Removing Sprocket Shaft Inner Timken Bearing (Typical) 2809 Figure 3-78. Install Claws on Snap Ring Crankshaft Bearing Tool (Part No HD-9457-101) b0807x3x Figure 3-77. Sprocket Shaft Outer Race Removal Figure 3-79. Remove Snap-Ring From Crankcase Bore 2002 Buell S3T: Engine 3-53...
Page 204 (OD) of the inner race and the smallest measured inside diameter (ID) of the outer race (crankcase bushing). A running clearance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. 3-54 2002 Buell S3T: Engine...
Page 205 (39.7459-39.7510 mm) Smallest Green 1.5650-1.5652 in. * Package color (39.7510-39.7561 mm) * Stamped number inside crankcase near race Figure 3-84. Bearing Identiﬁcation SERVICE WEAR LIMIT: 1.5672 in. (39.8069 mm) Figure 3-82. Factory Outer Race Sizes 2002 Buell S3T: Engine 3-55...
Page 206 With a 1.5651 in. (39.754 mm) ID outer race and a CAP (Part No. HD-95652-43A), and BEARING SEPARA- 1.2499 in. (31.747 mm) OD inner race, a blue bear- TOR (SNAP-ON TOOLS Stock No. CJ950). Apply heat to race to aid removal. ing is required. 3-56 2002 Buell S3T: Engine...
Page 207 ﬁne lapping compound. 1.145" (29.08 mm) 1.135" (28.83 mm) 1.272" (32.31 mm) 1.262" (32.05 mm) Figure 3-86. Pinion Shaft Bearing Tools 3546a Crankcase Main Bearing Lapping Tool (Part No. HD-96710-40B) Figure 3-87. Lapping Pinion Shaft Main Bearing 2002 Buell S3T: Engine 3-57...
Page 208 31.755- 31.760- 31.765- 31.770- 31.775- 31.780- 31.786- 3.791- 31.745 mm 31.750 mm 31.755 mm 31.760 mm 31.765 mm 31.770 mm 31.755 mm 31.780 mm 31.786 mm 31.791 mm 31.796 mm FACTORY COLOR CODE Green White 3-58 2002 Buell S3T: Engine...
Page 209 (5) and into installer base (1). Press race into bore until ﬁrmly seated against retaining ring (3). NOTE Figure 3-93. Use SPROCKET SHAFT BEARING/SEAL INSTALLATION TOOL (Part No. HD-42579) to install sprocket shaft tapered roller bearings and seal. 2002 Buell S3T: Engine 3-59...
Page 210 SPROCKET SHAFT SEAL/SPACER INSTALLER (Part No. HD-45206) onto sprocket shaft. Follow procedure in Step 8. Seal Rotate handle clockwise until the spacer makes contact with the bearing. Remove tool from sprocket shaft. Figure 3-92. Install Spacer in Seal 3-60 2002 Buell S3T: Engine...
Page 211 Be sure to reﬁll transmission to proper level with fresh lubri- cant. See CLUTCH. 23. See 3.4 INSTALLING THE ENGINE and perform the Head Screw with Ball Inside applicable steps. Cylinder Stud Shoulder on Cylinder Stud Air Gun Figure 3-95. Cylinder Studs 2002 Buell S3T: Engine 3-61...
Page 212 HOME NOTES 3-62 2002 Buell S3T: Engine...
Page 213 INTERNAL ENGINE PASSAGES RETURN OIL FEED OIL RETURN OIL FEED OIL 2002 Buell S3T: Engine 3-63...
Page 214 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 215 SUBJECT PAGE NO. 4.32 Engine Temperature Sensor ........4.33 Bank Angle Sensor .
Page 216: Specifications
18-23 ft-lbs. Ignition Bracket Screw 25-30 ft-lbs 34-41 Nm Intake Manifold Screws 6-10 ft-lbs 8-14 Nm Snorkel Plate Screws 6-8 ft-lbs 8-11 Nm LOCTITE THREADLOCKER 243 (blue) Tie Bar Bolts 30-33 ft-lbs 41-45 Nm 2002 Buell S3T: Fuel System...
Page 217: Dynamic Digital Fuel Injection
INTRODUCTION GENERAL The Buell Dynamic Digital Fuel Injection (DDFI) System pro- The Buell DDFI operates both as an open and closed loop vides microprocessor-based electronic engine management system which allows it to adjust for all possible operating con- for the 1203cc Buell Thunderstorm engine. The DDFI system ditions.
Page 218 12-place black connector [10] one 12-place gray connector [11] WIRE COLOR CODES USED IN THIS DOCUMENT Light Gray Violet Black Orange White Blue Pink Yellow Brown Green Figure 4-1. Buell Dynamic Digital Fuel Injection 2002 Buell S3T: Fuel System...
Page 219: Diagnostic Introduction
After repairs are performed, the work must be validated. This involves clearing the trouble codes and conﬁrming Figure 4-3. Scanalyzer (Part No. HD-41325) proper vehicle operation as indicated by the behavior of the check engine lamp. 2002 Buell S3T: Fuel System...
Page 220: Checking For Trouble Codes
Key ON Lamp remains ON: current trouble code* 4 Sec. 4 Sec. * Historic trouble code may exist Key ON ** Trouble codes 53-55, ECM failure & 56, crankshaft/camshaft timing Figure 4-5. Check Engine Lamp Operation 2002 Buell S3T: Fuel System...
Page 221 ECM will reduce engine power to assist in cooling the engine down to a safe operating temperature. The check engine lamp will blink until the engine has cooled to a safe operating temperature. 2002 Buell S3T: Fuel System...
Page 222: Scanalyzer
ECM. Once communications is established with the Figure 4-7. Scanalyzer and Cartridge ECM, the diagnostic menu appears. See Figure 4-8. Continue with the instructions under USAGE. 2002 Buell S3T: Fuel System...
Page 223 CHECK ENG= LAMP OFF TROUBLE CODE MENU 1- Display Current 2- Display Historic 3- Clear Historic MODE SYSTEM ID P/N 31652-99Y MODE BUEGC0B0 NOTE The system ID part number varies depending upon market. Figure 4-8. Scanalyzer Menus 2002 Buell S3T: Fuel System...
Page 224 Unplug Scanalyzer from data link connector. Install pro- tective plug connector. Attach data link connector to frame. Road test vehicle and observe check engine lamp. Con- ﬁrm proper operation without the reoccurrence of trouble codes. See 4.4 CHECKING FOR TROUBLE CODES. 2002 Buell S3T: Fuel System...
Page 225: Check Engine Lamp Diagnostics
Once all codes have been sent, the data string is repeated. When you have recorded the same trouble code twice, it is an indication that the transmission has been restarted and that all trouble codes have been retrieved. 4-10 2002 Buell S3T: Fuel System...
Page 226 Turn the ignition/light key switch OFF. Start the vehicle. 10. Install protective cover over data link connector. Attach Let it run for at least 30 seconds. connector to trunk. 11. Install seat. See 2.35 SEAT. Turn the engine off. 2002 Buell S3T: Fuel System 4-11...
Page 227: Breakout Box
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install tail section and seat. See 2.33 TAIL SECTION. 4-12 2002 Buell S3T: Fuel System...
Page 228: Wiggle Test
If a current trouble code is present when the wiggle test is entered, the Scanalyzer will respond as described immedi- ately upon entering the wiggle test mode. With key ON and engine off, clear trouble codes and then perform wiggle test with vehicle running. 2002 Buell S3T: Fuel System 4-13...
Page 229: Initial Diagnostic Check
If no problems are found after completion of the diagnos- tic check, a comparison of Scanalyzer parameters may be used to help locate intermittents and out-of-speciﬁcation sen- sors. See Table 4-1. 4-14 2002 Buell S3T: Fuel System...
Page 230 Improper fuel pressure 4.14 FUEL PRESSURE change seals. TEST. Ignition coil 4.16 MISFIRE. Leaky injectors Test fuel injectors. See 4.40 THROTTLE BODY AND INTAKE MANIFOLD. Valve sticking See Section 3 of a 1998 ser- vice manual. 2002 Buell S3T: Fuel System 4-15...
Page 231 Bank Angle Sensor 4.26 TROUBLE CODE 44 page 4-78 52, 53, 54, 55 ECM Failure 4.27 TROUBLE CODES 52, 53, 54 AND 55 page 4-82 Cam Sync Failure 4.28 TROUBLE CODE 56 page 4-83 4-16 2002 Buell S3T: Fuel System...
Page 232 Table 4-6. Wire Harness Connectors in Figure 4-16. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [11] ECM (gray) 12-place Deutsch under tail section [91A] Data Link 4-place Deutsch in trunk 2002 Buell S3T: Fuel System 4-17...
Page 233 Table 4-5. typical ranges? 4.8 WIGGLE TEST. Refer to diagnostic If Wiggle Test does not tips in related trouble recreate condition, refer code chart (even if to symptoms tables. no code is set). 7110 4-18 2002 Buell S3T: Fuel System...
Page 234 [10B] Continuity present in all four circumstances? Check Scanalyzer on Inspect terminals another vehicle. for damage or repair Scanalyzer OK? opens as necessary. 7120 Scanalyzer Replace ECM. See 4.29 malfunction. ELECTRONIC CONTROL MODULE. 7125 2002 Buell S3T: Fuel System 4-19...
Page 235: Check Engine Lamp Not Illuminated At Key On 4.10
BK/Y wire between connectors [39] and [10]. Figure 4-18. Electronic Control Module If no continuity, check for damaged/open wires in the check engine lamp circuit. 6936 Check Engine Bulb (O and BK/Y wires) Figure 4-19. Check Engine Lamp Bulb 4-20 2002 Buell S3T: Fuel System...
Page 236 Figure 4-20. Check Engine Lamp Circuit Table 4-7. Wire Harness Connectors in Figure 4-20. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [39] Main harness to instruments 10-place Multilock under fuel cell 2002 Buell S3T: Fuel System 4-21...
Page 237 Repair open or Repair open on O short to voltage on wire that feeds bulb BK/Y wire between or open on wire connector [39] and from bulb to con- connector [10B]. nector [39]. 7140 7145 4-22 2002 Buell S3T: Fuel System...
Page 238: Check Engine Lamp On Continuously
If the lamp goes off when the black b0548xox ECM connector [10] is unplugged, the BK/Y wire is not Figure 4-21. Check Engine Lamp shorted to ground. 6929 ECM Connector [10] (Black) ECM Connector [11] (Gray) Figure 4-22. Electronic Control Module 2002 Buell S3T: Fuel System 4-23...
Page 239 Figure 4-23. Check Engine Lamp Circuit Table 4-8. Wire Harness Connectors in Figure 4-23. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [39] Main harness to instruments 10-place Multilock under fuel cell 4-24 2002 Buell S3T: Fuel System...
Page 240 OK. Check for 4.29 ELECTRONIC on BK/Y wire between on BK/Y wire between trouble codes. See CONTROL MODULE. connector [39] and connector [39] and CHECKING FOR lamp in tachometer. connector [10]. TROUBLE CODES. 7150 7165 7160 2002 Buell S3T: Fuel System 4-25...
Page 241: Engine Cranks But Will Not Start
[10] ECM (black) 12-place Deutsch under tail section [11] ECM (gray) 12-place Deutsch under tail section [14] CMP Sensor 3-place Deutsch next to starter [18] Ignition Coil 3-place Packard under fuel cell, left side 4-26 2002 Buell S3T: Fuel System...
Page 242 Switch [22] Cam Position Fuel BE/O Sensor [14] Pump b0527x4x Y/BE b0617x4x Bank Angle Sensor [86] Ignition Coil [83] [134] GN/W BK/W Connector [10] Connector [11] Electronic Control Module (ECM) Figure 4-26. Ignition Circuit 2002 Buell S3T: Fuel System 4-27...
Page 243 46-53 PSI (317-365 kPa). Adequate pressure? Go to Test 4.12 STOP Incorrect pressure. See 4.14 (Part 2 of 3). FUEL PRESSURE TEST. 7195 4-28 2002 Buell S3T: Fuel System...
Page 244 (Part 3 of 3). Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Repair open circuit. 7240 Replace ECM. See Repair short 4.29 ELECTRONIC to ground. CONTROL MODULE. 7241 7250 2002 Buell S3T: Fuel System 4-29...
Page 245 7255 Repair. Replace cam Replace cam Mechanical failure. position sensor. 7260 position sensor. Inspect for loose See Section 7. See Section 7. rotor cup and 7265 sheared pinion 7265 gear key. 7255 4-30 2002 Buell S3T: Fuel System...
Page 246: No Ecm Power
Test 4.13 ﬂow chart. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. 6753 Neutral Switch behind Transmission Sprocket Connector [95] Clutch Switch Figure 4-29. Clutch Switch Figure 4-27. Neutral Switch 2002 Buell S3T: Fuel System 4-31...
Page 247 Table 4-10. Wire Harness Connectors in Figure 4-30. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [22] Right Handlebar Switch 4-place under fuel cell, right side [95] Clutch Switch 2-place clutch lever bracket 4-32 2002 Buell S3T: Fuel System...
Page 248 Replace ignition on right handlebar con- relay. See nector [22] GY/O wire. RELAY BLOCK. Voltage present? 7276 Repair open on W/BK Replace handlebar wire between connector switch assembly. [22] and ignition relay. 7278 7277 2002 Buell S3T: Fuel System 4-33...
Page 249: Fuel Pressure Test
Open and close the air bleed petcock (4) to purge the fuel pressure gauge and hose of air. Repeat this step several times until only solid fuel (without bub- bles) ﬂows from the air bleed tube (5). Close the air bleed petcock (4). 4-34 2002 Buell S3T: Fuel System...
Page 250 Test 4.14 ﬂow charts. Figure 4-34. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404), gray socket probe and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. Figure 4-34. Harness Connector Kit 2002 Buell S3T: Fuel System 4-35...
Page 251 Table 4-11. Wire Harness Connectors in Figure 4-35. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [39] Instruments 10-place Multilock under fuel cell [86] Fuel Pump 4-place Packard above rear cylinder head, left side 4-36 2002 Buell S3T: Fuel System...
Page 252 7457 key ON. Is voltage greater than 1 VDC? Locate and repair poor Replace ignition relay. connection between bat- See Section 7. tery and ignition relay. 7458 7456 2002 Buell S3T: Fuel System 4-37...
Page 253 3. Is continuity present? Replace fuel pump Repair fuel pump assembly. See 4.39 wiring. FUEL PUMP. 7463 7462 Replace ECM. See 4.29 Locate and repair open ELECTRONIC CONTROL on BN/Y wire. MODULE. 7466 7464 4-38 2002 Buell S3T: Fuel System...
Page 254: Idle Speed Control
Figure 4-36. Use the adjuster attached to the throttle body to make idle speed adjustments. Normal idle speed 850-1050 RPM. Idle Adjustment Screw (Cable not shown) Stop Plate Figure 4-36. Idle Adjustment Screw (Typical) 2002 Buell S3T: Fuel System 4-39...
Page 255: Misfire
Using an ohmmeter, touch probes to terminals on each end plug wire. Compare resistance values to Table 4-12. Replace cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable. 4-40 2002 Buell S3T: Fuel System...
Page 256 Table 4-13. Wire Harness Connectors in Figure 4-38. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [22] Right Handlebar Switch 4-place under fuel cell [83] Coil 3-place Packard under fuel cell, left side 2002 Buell S3T: Fuel System 4-41...
Page 257 Replace known to be good. ignition coil. Perform spark test. 7535 Did spark jump gap during engine cranking? Original ignition coil Go to Test 4.16 is faulty. Replace. STOP (Part 2 of 2). 7535 4-42 2002 Buell S3T: Fuel System...
Page 258 1.0 ohm? Replace cam sensor Find source with a unit known of intermittent to be good. Does and repair. problem still exist? 7540 Install original cam sensor. Replace ECM. 4.29 ELECTRONIC 7542 CONTROL MODULE. 7541 2002 Buell S3T: Fuel System 4-43...
Page 259: Trouble Code 11
As the throttle is slowly moved, the voltage should change gradually without spikes or low voltages being observed. Scanalyzer Notes The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. 4-44 2002 Buell S3T: Fuel System...
Page 260 Table 4-14. Wire Harness Connectors in Figure 4-41. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under tail section [14] Cam Position Sensor 3-place Deutsch near starter [88] TP Sensor 3-place Packard behind air cleaner backplate 2002 Buell S3T: Fuel System 4-45...
Page 261 R/W wire and short between V/Y ELECTRONIC CONTROL battery voltage. wire and R/W wire. 7570 MODULE). Road test again 7585 to verify. 7586 7565 Clear codes and conﬁrm proper operation with no check engine lamp. 4-46 2002 Buell S3T: Fuel System...
Page 262 1 megaohm? Replace ECM. See 4.29 Locate and repair short ELECTRONIC CONTROL between R/W and BK/W MODULE. wires. Reconnect [14]. Clear codes and conﬁrm proper operation with no check engine 7591 7592 lamp. 2002 Buell S3T: Fuel System 4-47...
Page 263: Trouble Code 13
If fresh air enters exhaust system, the O2 sen- sor will read a lean condition, causing the system to go rich. Diagnostic Notes Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. 4-48 2002 Buell S3T: Fuel System...
Page 264 Electronic Control Module (ECM) Figure 4-44. Oxygen Sensor Circuit Table 4-15. Wire Harness Connectors in Figure 4-44. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under tail section [137] Oxygen Sensor 1-place above starter 2002 Buell S3T: Fuel System 4-49...
Page 265 4.29 ELECTRONIC 4.29 ELECTRONIC voltage and repair. V/GY wire. CONTROL MODULE. CONTROL MODULE. 7657 7658 7659 7656 Clear codes and conﬁrm proper operation with no check engine lamp. 4-50 2002 Buell S3T: Fuel System...
Page 266 Air leak 7662 present? Repair. Fuel injectors may be dirty. See Fuel Injectors 7663 under 4.40 THROTTLE BODY AND INTAKE MANIFOLD. Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell S3T: Fuel System 4-51...
Page 267 CODE 13? Install original O2 sensor System and replace ECM (4.29 now OK. ELECTRONIC CON- 7672 TROL MODULE). Road test again to verify. 7671 Clear codes and conﬁrm proper operation with no check engine lamp. 4-52 2002 Buell S3T: Fuel System...
Page 268 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. Scanalyzer Notes The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. 2002 Buell S3T: Fuel System 4-53...
Page 269 Figure 4-45. Engine Temperature Sensor Circuit Table 4-17. Wire Harness Connectors in Figure 4-45. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under tail section [90] Engine Temperature Sensor 1-place bullet above rear cylinder head, left side 4-54 2002 Buell S3T: Fuel System...
Page 270 Dis- lamp. regard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location. 2002 Buell S3T: Fuel System 4-55...
Page 271 (but not the instruction box) if your volts and repair. normal progression through the chart brings you to this location. 7690 Clear codes and conﬁrm proper operation with no check engine lamp. 4-56 2002 Buell S3T: Fuel System...
Page 272 10 of [11] and system ground (Terminals 2 and 11 of [10]). table may be used to test the ET sensor at various tem- perature levels in order to evaluate the possibility of a shifted (out-of-calibration) sensor which may result in driveability problems. 2002 Buell S3T: Fuel System 4-57...
Page 273 Figure 4-46. Intake Air Temperature Sensor Circuit Table 4-19. Wire Harness Connectors in Figure 4-46. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under tail section [89] IAT Sensor 2-place Deutsch inside air box 4-58 2002 Buell S3T: Fuel System...
Page 274 (but not the instruction box) if your short to 12 volts normal progression through the chart brings you to and repair. this location. 7745 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell S3T: Fuel System 4-59...
Page 275 (but not the instruc- 7750 tion box) if your normal progression 7755 through the chart brings you to this location. Clear codes and conﬁrm proper operation with no check engine lamp. 4-60 2002 Buell S3T: Fuel System...
Page 276: Battery Voltage
DIAGNOSTICS/TROUBLESHOOTING. Scanalyzer Notes The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. Figure 4-48. Fuse Holder 2002 Buell S3T: Fuel System 4-61...
Page 277 Ignition Ground Connector [10] Connector [11] Electronic Control Module (ECM) Figure 4-49. Battery Voltage Circuit Table 4-20. Wire Harness Connectors in Figure 4-49. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section 4-62 2002 Buell S3T: Fuel System...
Page 278 Is voltage drop greater than 0.5 volt? Replace ignition relay. 7.9 RELAY BLOCK. STOP 7767 Go to Code 16 Test (Part 2 of 2). Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell S3T: Fuel System 4-63...
Page 279 ON. 7780 Is voltage drop greater than 0.5 volt? Replace BK wire between circuit breaker Replace circuit and battery. breaker. 7784 7779 Clear codes and conﬁrm proper operation with no check engine lamp. 4-64 2002 Buell S3T: Fuel System...
Page 280: Trouble Codes 23 And 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 And
The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. If a number is printed next to the icon, then refer to the Scanalyzer notes at the bot- tom of the ﬂow chart. 2002 Buell S3T: Fuel System 4-65...
Page 281 Figure 4-52. Fuel Injector Circuit Table 4-21. Wire Harness Connectors in Figure 4-52. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [84] Front Injector 2-place under fuel cell [85] Rear Injector 2-place under fuel cell 4-66 2002 Buell S3T: Fuel System...
Page 282 Test Mode) can be used to turn fuel pump on for or rear injector once each second for a total of ﬁve periods up to 30 seconds. Power to the pump also seconds. includes power to the fuel injectors and ignition coil. 2002 Buell S3T: Fuel System 4-67...
Page 283 Test Mode) can be used to turn fuel pump on for or rear injector once each second for a total of ﬁve periods up to 30 seconds. Power to the pump also seconds. includes power to the fuel injectors and ignition coil. 4-68 2002 Buell S3T: Fuel System...
Page 284 Scanalyzer can be used. If a number is printed next to the icon, then refer to the Scanalyzer notes at the bot- tom of the ﬂow chart. Battery Figure 4-54. Testing Ignition Coil Connectors 2002 Buell S3T: Fuel System 4-69...
Page 285 Figure 4-55. Ignition Coil Circuit Table 4-22. Wire Harness Connectors in Figure 4-55. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [83] Ignition Coil Connector 3-place Packard under fuel cell, left side 4-70 2002 Buell S3T: Fuel System...
Page 286 Test Mode) can be used to turn fuel pump on for or rear injector once each second for a total of ﬁve periods up to 30 seconds. Power to the pump also seconds. includes power to the fuel injectors and ignition coil. 2002 Buell S3T: Fuel System 4-71...
Page 287: Trouble Code 33
Scanalyzer Notes The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. Ignition Fuse Spare Fuse Slot (may be 15 or 20 amp) Figure 4-57. Ignition Fuse 4-72 2002 Buell S3T: Fuel System...
Page 288 Table 4-23. Wire Harness Connectors in Figure 4-58. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [39] Instruments 10-place Multilock under fuel cell [86] Fuel Pump 4-place Packard above rear cylinder head, left side 2002 Buell S3T: Fuel System 4-73...
Page 289 (4.39 FUEL PUMP) and replace ECM (4.29 ELECTRONIC CONTROL MODULE). 7893 7892 Replace fuel pump. See Repair 4.39 FUEL PUMP. open. 7897 7898 Clear codes and conﬁrm proper operation with no check engine lamp. 4-74 2002 Buell S3T: Fuel System...
Page 290: Trouble Code 35
Inadequate safety precautions could result in death or serious injury. Purge fuel line and remove fuel tank to access instru- ment connector [39]. See 4.36 FUEL TANK. Replace tachometer. See 7.13 TACHOMETER. Figure 4-60. Instrument Connector [39] 2002 Buell S3T: Fuel System 4-75...
Page 291 (ECM) Figure 4-61. Tachometer Circuit Table 4-24. Wire Harness Connectors in Figure 4-61. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [39] Main Harness to Instruments 10-place Multilock under fuel cell 4-76 2002 Buell S3T: Fuel System...
Page 292 Reconnect [39]. Locate Replace ECM. See intermittents using 4.29 ELECTRONIC WIGGLE TEST. Intermit- CONTROL MODULE. tents found? 7882 Repair. Replace tachometer. 7881 7883 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell S3T: Fuel System 4-77...
Page 293: Trouble Code 44
41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. When vehicle lean angle exceeds 55°, ECM shuts off ignition and fuel systems. Figure 4-63. Normal Bank Angle Sensor Operation 4-78 2002 Buell S3T: Fuel System...
Page 294 Figure 4-64. Bank Angle Sensor Circuit Table 4-25. Wire Harness Connectors in Figure 4-64. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under tail section [134] Bank Angle Sensor 3-place Packard under tail section, right side 2002 Buell S3T: Fuel System 4-79...
Page 295 Install bank angle sensor 0.25 in. (6.4 mm) of sides, face or properly. See 4.33 BANK top of bank angle sensor? ANGLE SENSOR. 7976 Replace bank angle sensor. Return to original 4.33 BANK ANGLE configuration. SENSOR. 4-80 2002 Buell S3T: Fuel System...
Page 296 Is continuity present? 7975 Replace ECM. See 4.29 Repair short to ground ELECTRONIC CONTROL on Lt GN/GY wire. MODULE. Check for codes. 7973 7974 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell S3T: Fuel System 4-81...
Page 297: Trouble Code
Code 54 - EE PROM failure. ● Code 55 - Microprocessor failure. NOTE Dealership technicians ﬁling warranty claims should use job/ time code 7913 for all Code 52, 53, 54 and 55 ECM replace- ments. 4-82 2002 Buell S3T: Fuel System...
Page 298 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), black pin probes and patch cord. Timer Plate Stud (2) 4.30 CAM POSITION SENSOR AND ROTOR. Sensor Wiring Cam Position Sensor b0313a7x Figure 4-65. Cam Position Sensor 2002 Buell S3T: Fuel System 4-83...
Page 299 Table 4-26. Wire Harness Connectors in Figure 4-66. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under tail section [14] Cam Position Sensor 3-place Deutsch near starter [88] TP Sensor 3-place Packard behind air cleaner backplate 4-84 2002 Buell S3T: Fuel System...
Page 300 4.29 ELEC- connectors [11] and connectors [11] and to ground. to voltage. TRONIC CON- [14]. [14]. TROL MODULE. 7970 7955 7965 7945 7945 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell S3T: Fuel System 4-85...
Page 301 7940 7951 Install original cam posi- System tion sensor. Replace ECM. See 4.29 ELEC- TRONIC CONTROL 7952 MODULE. 7960 Clear codes and conﬁrm proper operation with no check engine lamp. 4-86 2002 Buell S3T: Fuel System...
Page 302: Electronic Control Module
Figure 4-67. Electronic Control Module (ECM) injury. Install tail section and seat. See 2.33 TAIL SECTION. 2002 Buell S3T: Fuel System 4-87...
Page 303 Sensor ground 1 Injector rear output Sensor ground 2 No function Engine temperature input Bank angle sensor input Intake air temperature input System ground B (coil) Serial data receive Tachometer out Serial data transmit 4-88 2002 Buell S3T: Fuel System...
Page 304: Cam Position Sensor And Rotor
11. Carefully remove camshaft oil seal if damaged or if there Install cam position sensor and timer plate studs. Rotate is any evidence of oil leakage past the seal. cam position sensor to its previously marked position to obtain approximate ignition timing. 2002 Buell S3T: Fuel System 4-89...
Page 305 10. Secure timer cover to inner cover using new rivets. 11. Install right fairing lower. See 2.38 FAIRING LOWERS. 12. Install negative battery cable to battery. Figure 4-72. Connecting Sensor Wires 4-90 2002 Buell S3T: Fuel System...
Page 306: Oxygen Sensor
Apply LOCTITE ANTI-SEIZE LUBRICANT to threads of sensor. Make sure anti-seize is marked as safe for use with O2 sensors. Figure 4-73. Thread sensor into exhaust header. Tighten to 42-45 ft-lbs (57-61 Nm). Connect 1-place connector [137] to wiring harness. 2002 Buell S3T: Fuel System 4-91...
Page 307: Engine Temperature Sensor
Route ET sensor wire lead through opening at rear of cylinder head, under rocker box and cover and connect ET sensor 1-place connector [90] to wiring harness. Install fuel tank. See 4.36 FUEL TANK. 4-92 2002 Buell S3T: Fuel System...
Page 308: Bank Angle Sensor
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install tail section and seat. See 2.33 TAIL SECTION. 2002 Buell S3T: Fuel System 4-93...
Page 309: Intake Air Temperature Sensor
ﬁlter foam gasket that ﬁts against the backing plate. Figure 4-78. Intake Air Temperature Sensor Installed Position air ﬁlter on air cleaner backing plate. Install air cleaner cover and air ﬁlter. See 4.41 AIR CLEANER. 4-94 2002 Buell S3T: Fuel System...
Page 310: Throttle Position Sensor
TP degree reading reaches 5.8. Start engine and bring the engine temperature to a minimum of 265° F (129.4° C). Set the warm idle speed at 1000-1100 rpm with the idle adjuster cable. 2002 Buell S3T: Fuel System 4-95...
Page 311: Fuel Tank
Vent Valve Assembly CAUTION Use caution when removing fuel tank. If tank should con- tact other chassis parts, tank ﬁnish may be damaged. Remove fuel tank from frame. Figure 4-83. Vapor Vent Valve 4-96 2002 Buell S3T: Fuel System...
Page 312 Add cleaning agent. Replace fuel cap to seal tank. Shake tank to agitate agent. Thoroughly ﬂush fuel tank after cleaning. Allow tank to air dry. Carefully inspect fuel hose and vent hose for damage, wear or general deterioration. Replace as necessary. 2002 Buell S3T: Fuel System 4-97...
Page 313 Octane rating is usually found on the pump. 10. Fill fuel tank. Turn ignition key ON and listen for fuel pump activation. 11. Carefully inspect for leaks. Perform fuel pressure test if necessary. 4-98 2002 Buell S3T: Fuel System...
Page 314: Fuel Tank Vent Valve
ﬁtting from vent valve. oriented to 12:00 position when ﬁtting is tightened ﬁnger Pull the vent valve from the gasket and remove from fuel tight. Make sure O-ring remains in groove of ﬁtting while tank. tightening. 2002 Buell S3T: Fuel System 4-99...
Page 315 Fill fuel tank with proper fuel (91 Octane) and install gas cap. 10. Connect negative battery cable. Tighten to 40 in-lbs (4.5 Figure 4-87. Fuel Tank Vent Alignment Nm). 11. Pressurize fuel system. 12. Check for leaks. 4-100 2002 Buell S3T: Fuel System...
Page 316: Inline Fuel Filter
ﬂow. Make sure to push fuel hoses all the way on to ﬁttings and position hose clamp on ﬁtting side of barb. Install fuel tank. See 4.36 FUEL TANK. Pressurize fuel system and check for leaks. 2002 Buell S3T: Fuel System 4-101...
Page 317: Fuel Pump
Press pump ﬁtting outlet into pump holder housing (2). Place a new retaining clamp (5) over pump body. Posi- tion clamp inside groove (8) on pump holder housing. 4-102 2002 Buell S3T: Fuel System...
Page 318 Brass Adaptor Install new O-ring on brass adaptor nut (for fuel stud). Install rubber seal, sealing washer and washer on electri- cal outlet stud. Figure 4-93. Rubber Seals and Washers 2002 Buell S3T: Fuel System 4-103...
Page 319: Throttle Body And Intake Manifold
Screw (metric) 10. Injector Seals (4) 11. Injector (2) 12. Intake Manifold 13. Screw (4) 14. Intake Flange (2, Front and Rear) 15. Intake Seal (2) b0784x4x Figure 4-94. Throttle Body and Intake Manifold 4-104 2002 Buell S3T: Fuel System...
Page 320: Fuel Injectors
Remove screw (3) (metric) that holds the fuel rail to have taken a deﬁnite set. the manifold. Separate fuel rail from injectors (1, 2) by gently rock- ing the fuel rail and pulling it away from the injectors. 2002 Buell S3T: Fuel System 4-105...
Page 321 Install screw and throttle cable clamps to throttle cables. Verify operation by turning throttle grip and observ- Cable End ing the cable action and throttle valve movement. Guide Slot Figure 4-99. Idle Control Cable Installation 4-106 2002 Buell S3T: Fuel System...
Page 322 Calibrate throttle position sensor if removed or replaced. 4.35 THROTTLE POSITION SENSOR. 10. Install air cleaner backplate and cover. See 4.41 AIR CLEANER. 11. Check throttle cable adjustment. 6-10 ft-lbs (8-14 Nm) Figure 4-101. Intake Flange Screws, Primary Cover Side 2002 Buell S3T: Fuel System 4-107...
Page 323: Air Cleaner
Remove front breather bolt (4). Pull backplate (5) away from motorcycle and rear breather hose (3). On California models, slide fresh air inlet hose from carbon canister through backplate. Remove breather gasket from backplate. 4-108 2002 Buell S3T: Fuel System...
Page 324 Front Breather Bolt Spacer Screw Backplate Inspect ﬁlter element. See 1.18 AIR CLEANER. Rear Breather Hose Figure 4-103. Place ﬁlter element in ﬁlter box (2). Attach ﬁlter box to snorkel (1). Figure 4-108. Air Cleaner Spacer 2002 Buell S3T: Fuel System 4-109...
Page 325: Evaporative Emissions Control
HOME EVAPORATIVE EMISSIONS CONTROL 4.42 GENERAL Buell motorcycles sold in the state of California are equipped Post with an evaporative (EVAP) emissions control system. The Check Ball EVAP system prevents fuel hydrocarbon vapors from escap- ing into the atmosphere and is designed to meet the Califor- nia Air Resource Board (CARB) regulations in effect at the time of manufacture.
Page 326 Screw, Washer and Locknut (2) in death or serious injury. Install vent valve. See 4.37 FUEL TANK VENT VALVE. Figure 4-110. Attach fuel tank vent hose (1) to can- ister if disconnected. Figure 4-112. Carbon Canister Mounting 2002 Buell S3T: Fuel System 4-111...
Page 327 (2) to the carbon canister. Canister vent hose attaches to the top ﬁtting. Make sure to push fuel tank vent hose all the way on to carbon canister ﬁtting and position hose clamp on ﬁtting side of barb. 4-112 2002 Buell S3T: Fuel System...
Page 328 Table Of Contents ELECTRIC STARTER SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 330: Electric Starter
8.1 ft-lbs (11 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Battery Terminal Bolts 60-96 in-lbs 7-11 Nm metric Starter Battery Positive 60-85 in-lbs 7-10 Nm metric Cable Nut Starter Mounting Bolts 13-20 ft-lbs 18-27 Nm 2001 Buell S3/S3T: Electric Starter...
Page 331: 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). 2001 Buell S3/S3T: Electric Starter...
Page 332 Idler Gear Field Winding Armature Brush Ball Bearing Solenoid Plunger Main Solenoid Contacts Battery 10. Pull-in Winding Starting circuit-see 11. Hold-in Winding wiring diagram 12. Overrunning Clutch 13. Clutch Ring Gear Figure 5-1. Starter Operation 2001 Buell S3/S3T: Electric Starter...
Page 333 Replace. Armature winding grounded or short- Replace. circuit. Reduction gears damaged. Replace. Insufﬁcient brush spring tension. Replace. Disconnected lead wire between Repair or replace lead wire. solenoid and ﬁeld windings. Ball bearing sticks. Replace bearing. 2001 Buell S3/S3T: Electric Starter...
Page 334 Coil layer shorted. Replace solenoid. running. Contact plate melted and stuck. Replace solenoid. Starting switch or Unopened contacts. Replace starting switch or starter starter relay. relay. Poor returning. Replace starting switch or starter relay. 2001 Buell S3/S3T: Electric Starter...
Page 335: Starting System Diagnosis
Circuit or Button to Relay. Battery Voltage Present? Correct Relay 5831 5832 Ground. 5828 Replace Right Repair Wiring to Motor Terminal Battery Terminal Handlebar Starter Button. Switchgear. 5831 5816 Figure 5-2. Starting System Diagnosis, Part 1 2001 Buell S3/S3T: Electric Starter...
Page 336 Test Starter Motor TESTING. Primary Drive. for Opens, Shorts or Grounds. FREE RUNNING CURRENT DRAW TEST under STARTER. Replace or Repair Starter Motor See DIAGNOSTICS in 7.6 STARTER INTERLOCK. 5817 Figure 5-3. Starting System Diagnosis, Part 2 2001 Buell S3/S3T: Electric Starter...
Page 337: Starter Activation Circuits
GROUND CIRCUIT 0.1A 0.1A 0.1A 0.1A 150A 150A 150A 150A Start Switch Starter Ignition Switch Relay Battery Ignition Circuit Breaker Solenoid Main Circuit Breaker Figure 5-4. Typical Circuity. Refer to wiring diagrams for more information. 2001 Buell S3/S3T: Electric Starter...
Page 338: Diagnostics/Troubleshooting
Typically, a good circuit will drop less than 1 volt. If the voltage drop is greater, back track through the con- nections until the source of the potential difference is found. 2001 Buell S3/S3T: Electric Starter...
Page 339 HOME Figure 5-5. Electric Starting System Circuit 5-10 2001 Buell S3/S3T: Electric Starter...
Page 340: Starter System Testing
Typical starter current draw will range between 140- 180 amperes. If starter current draw exceeds 180 amperes, then the problem may be in the starter or starter drive. Remove starter for further tests. See REMOVAL. 2002 Buell S3T: Electric Starter 5-11...
Page 341: Starter
Check ammeter reading. problem with engine or primary drive. Ammeter should show 90 amps maximum. If reading is higher, disassemble starter for inspec- tion. See STARTER. 5-12 2002 Buell S3T: Electric Starter...
Page 342 Figure 5-14. Return Test Observe starter pinion. If starter pinion returns to its original position, sole- noid is working properly. If starter pinion does not return to its original posi- tion, replace the solenoid. 2002 Buell S3T: Electric Starter 5-13...
Page 343 Hold a thin steel strip (2) (hacksaw blade) against Brush Spring (4) armature core and slowly turn armature. Figure 5-17. Starter Components A shorted armature will cause the steel strip to vibrate and be attracted to the core. Replace shorted armatures. 5-14 2002 Buell S3T: Electric Starter...
Page 344 Touch one probe to any commutator segment (1). Touch the other probe to the armature core (2). There should be no continuity (inﬁnite ohms). If there is continuity, then the armature is grounded. Replace grounded armatures. 2002 Buell S3T: Electric Starter 5-15...
Page 345 Touch the other probe to each of the positive (insu- lated) brush holders (2). There should be no continuity (inﬁnite ohms). If there is continuity at either brush holder, replace the brush holder assembly. 5-16 2002 Buell S3T: Electric Starter...
Page 346 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 19. Gasket Figure 5-26. Starter Assembly 2002 Buell S3T: Electric Starter 5-17...
Page 347 Connect solenoid wire (4). Attach circuit breaker wire ring terminal (3). Attach positive battery cable ring terminal (2). Install nut with washer (1) (metric). Tighten to 60-85 in-lbs (7-10 Nm). Replace protective boot (if equipped). 5-18 2002 Buell S3T: Electric Starter...
Page 348: Starter Solenoid
Figure 5-27. Replace wire connection hardware as 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 S3T: Electric Starter 5-19...
Page 349 HOME NOTES 5-20 2002 Buell S3T: Electric Starter...
Page 350 DRIVE/TRANSMISSION 6 Table Of Contents SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Chain .
Page 352: Specifications
0.152 0.661 16.789 Clutch Pack minimum minimum NOTE Service wear limits are given as a guideline for measuring components that are not new. For measurement speciﬁca- tions not given under SERVICE WEAR LIMITS, see NEW COMPONENTS. 2002 Buell S3T: Drive/Transmission...
Page 353 Transmission Drain Plug 14-21 ft-lbs 19.0-28.5 Nm remove debris from end Transmission Sprocket Nut LOCTITE THREADLOCKER 262 (red), left hand See note threads, special torque turn method Transmission Sprocket Screws 90-110 in-lbs 10.2-12.4 Nm replace after 3 removals 2002 Buell S3T: Drive/Transmission...
Page 354: Primary Chain
Lockplate Wellnut Coupling Ramp Assembly Quad Ring Drain Plug and O-ring 10. Locknut 11. Chain Adjuster Screw 12. Primary Cover 13. Primary Chain Inspection Cover 14. Clutch Adjusting Screw 15. Oil Seal Figure 6-1. Primary Cover 2002 Buell S3T: Drive/Transmission...
Page 355 Thread adjuster screw into tapped boss at bottom of primary cover. At outside of cover, install locknut (2) onto adjuster screw with nylon sealing surface toward cover. Tighten to 20-25 ft-lbs (27- 34 Nm). Install primary cover. 2002 Buell S3T: Drive/Transmission...
Page 356 17. Tighten mounting bolt to 27-29 ft-lbs (37-39 Nm). 18. Install mufﬂer. See 2.27 EXHAUST SYSTEM. 19. Install left fairing lower. See 2.38 FAIRING LOWERS. 20. Connect negative cable to battery. Figure 6-6. Upper Clamp Position 2002 Buell S3T: Drive/Transmission...
Page 357: Drive Belt
Push rear wheel forward and slip off belt. Remove right rear isolator. See 2.20 REAR ISOLATORS. 10. Slide the drive belt from the sprockets between the frame and the swingarm mount block. 2002 Buell S3T: Drive/Transmission...
Page 358 Align the new belt and rear wheel. See 1.10 DRIVE BELT DEFLECTION. Install sprocket cover. See 2.29 SPROCKET COVER. Install the stone guard and lower belt guard. See 2.30 STONE GUARD. Connect negative battery cable to battery. 2002 Buell S3T: Drive/Transmission...
Page 359: Clutch Release Mechanism
Wellnut Outer Ramp Ball (3) O-Ring Cable End Fitting 10. Clutch Cable End 11. Primary Cover 12. Clutch Adjusting Screw 13. Retaining Ring 14. Quad Ring 15. Inner Ramp 16. Coupling Figure 6-10. Clutch Release Mechanism 2002 Buell S3T: Drive/Transmission...
Page 360 Turn adjusting screw counterclockwise until resis- tance is felt. 6240 Adjust clutch release mechanism. See CLUTCH. Connect negative battery cable to battery terminal. Outer Ramp Wellnut Adjusting Screw Cable End Coupling Slot of Primary Cover Figure 6-12. Nut and Outer Ramp 2002 Buell S3T: Drive/Transmission...
Page 361: 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. 6-10 2002 Buell S3T: Drive/Transmission...
Page 362 Turn compressing tool handle (5) clockwise until tool relieves pressure on snap ring (8) and spring seat (9). Remove and discard snap ring (8). Unseat spring seat (9) from the groove in clutch hub prongs. Remove pressure plate assembly. 2002 Buell S3T: Drive/Transmission 6-11...
Page 363 13. Release Plate 19. Steel Plate (6) 25. Bearing 20. Spring Plate 26. Clutch Shell 14. Retaining Ring 15. Bearing 21. Mainshaft Nut 27. Retaining Ring 16. Adjusting Screw 22. Washer Figure 6-16. Clutch Assembly 6-12 2002 Buell S3T: Drive/Transmission...
Page 364 6.5 PRIMARY DRIVE/ CLUTCH. Remove large retaining ring (1). 10. Remove clutch pack components. See Steps 4-5 of Remove adjusting screw assembly (2, 3 and 4) from CLUTCH PACK under 6.5 PRIMARY DRIVE/CLUTCH. pressure plate. 2002 Buell S3T: Drive/Transmission 6-13...
Page 365 Figure 6-20. Check the clutch shell. Inspect primary chain sprocket (1) and the starter ring gear (2) on the clutch shell. If either sprocket or ring gear are badly worn or damaged, replace the clutch shell. 6-14 2002 Buell S3T: Drive/Transmission...
Page 366 Place bearing inside release plate. Insert adjusting screw (4) through bearing and release plate (2). Secure with new retaining ring (3). Figure 6-21. Position diaphragm spring (1) with its concave side facing toward pressure plate onto pressure plate assembly. 2002 Buell S3T: Drive/Transmission 6-15...
Page 367 Clutch Hub assembly with retaining ring. Figure 6-24. Mainshaft Nut and Washer Install primary cover. See PRIMARY COVER under PRIMARY CHAIN. Install the left fairing lower. See 2.38 FAIRING LOWERS. Connect negative battery cable to battery. 6-16 2002 Buell S3T: Drive/Transmission...
Page 368: Transmission
The shifter fork drum moves shifter forks, which slide a series of shifter clutch gears, on the mainshaft and countershaft, into and out of mesh with the other gears. 2002 Buell S3T: Drive/Transmission 6-17...
Page 369 1st Gear XLH transpower flow 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 6-25. Transmission Power Flow 6-18 2002 Buell S3T: Drive/Transmission...
Page 370: Transmission Case
2.38 FAIRING LOW- Transmission Sprocket Nut (left-hand threads) ERS. Lockplate Socket Head Screw (4) 12. Remove clutch assembly, primary chain and engine Figure 6-27. Transmission Sprocket sprocket. See PRIMARY CHAIN/DRIVE under 6.5 PRI- MARY DRIVE/CLUTCH. 2002 Buell S3T: Drive/Transmission 6-19...
Page 371 Neutral Indicator Switch Figure 6-30. The neutral indicator switch is threaded into the transmission portion of the right crankcase half. See NEUTRAL INDICATOR SWITCH for testing, removal and Figure 6-30. Neutral Indicator Switch installation procedures. 6-20 2002 Buell S3T: Drive/Transmission...
Page 372: Shifter Forks And Drum
18. Detent Screw Shifter Fork Pin (3) 12. Locknut (2) 19. Mainshaft Bearing Neutral Indicator Pin 13. Detent Plate (Typical) 20. Countershaft Bearing 14. Washer (2) 21. Washer (2) Shifter Fork Drum Figure 6-31. Shifter Mechanism 2002 Buell S3T: Drive/Transmission 6-21...
Page 373 These parts are installed during NOTE transmission installation after the ﬁnal shifter pawl adjustment is made. See 6.13 TRANSMISSION INSTALLATION AND Figure 6-28. Install detent arm roller (3) between coun- SHIFTER PAWL ADJUSTMENT. tershaft bearing and detent plate. 6-22 2002 Buell S3T: Drive/Transmission...
Page 374: Mainshaft And Countershaft
Using RETAINING RING PLIERS (Part No. J-5586) remove and discard retaining ring (5) next to counter- shaft 5th gear (12). Slide countershaft 5th (12), mainshaft 2nd (22) and countershaft 2nd (11) off end of shafts. Figure 6-36. 2002 Buell S3T: Drive/Transmission 6-23...
Page 375 33. Ring, Retaining 20. Bearing, Needle 34. Nut, Mainshaft 21. Gear, Mainshaft 5th 35. Washer, Spring 22. Gear, Mainshaft 2nd 36. Bushing 23. Gear, Mainshaft 3rd 37. Bearing Closed (Shifter Shaft) Figure 6-37. Transmission Assembly 6-24 2002 Buell S3T: Drive/Transmission...
Page 376 Failure to comply could result in death or serious injury. 10. Remove thrust washer (6). Expand remaining retaining ring (5) and slide off shaft. This completes disassembly of countershaft. Figure 6-40. 2002 Buell S3T: Drive/Transmission 6-25...
Page 377 (28) resting on the section of pipe. Insert the splined end of the shaft through the bearing and hold in a vertical position. Press the shaft into the bearing until the bearing bottoms against the shaft shoulder. Figure 6-42. 6-26 2002 Buell S3T: Drive/Transmission...
Page 378 Hold assembly straight, making sure gear teeth on coun- tershaft are engaged with gear teeth on mainshaft, and press bearing onto shaft until beveled spacer bottoms against bearing. NOTE When correctly installed, countershaft 4th gear should have zero end play. Blocks Figure 6-45. 2002 Buell S3T: Drive/Transmission 6-27...
Page 379 (32). Insert TORX screw (32) through retention collar and thread into end of shaft. Place transmission in gear and tighten TORX screw to 13-17 ft-lbs (18-23 Nm). 20. Install shifter forks and drum. See 6.8 SHIFTER FORKS DRUM. Figure 6-48. 6-28 2002 Buell S3T: Drive/Transmission...
Page 380: Main Drive Gear
For Outer Bearing For Seal 0.06-0.03 in. (1.52-0.76 mm) Support Bracket Driver Bolt Thrust Washer 5th Gear Figure 6-51. Removing Main Drive Gear Main Drive Gear xlh0639 Needle Bearing Seal Figure 6-49. Main Drive Gear Assembly 2002 Buell S3T: Drive/Transmission 6-29...
Page 381 5th Gear until shoulder on gear (4) bottoms against inner race Bolt Washer of bearing. Installer Cup Figure 6-49. Tap in new seal (3) at threaded end of Figure 6-53. Main Drive Gear Installation 5th gear. 6-30 2002 Buell S3T: Drive/Transmission...
Page 382: Access Door Bearings
Shift Drum Bushing Figure 6-55. Shift Drum Bushing Assembly Retaining Ring Bearing, Mainshaft Retaining Ring Bearing, Countershaft Figure 6-54. Ball Bearing Assembly 2002 Buell S3T: Drive/Transmission 6-31...
Page 383: 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. 6-32 2002 Buell S3T: Drive/Transmission...
Page 384: Transmission Installation And Shifter Pawl Adjustment
Place new quad ring (17) over threaded end of ﬁfth gear (21), and position next to the gear taper. Install spacer (16) over threaded end of ﬁfth gear with chamfered end toward quad ring. Slide spacer up against bearing (19). 2002 Buell S3T: Drive/Transmission 6-33...
Page 385 12. If you cannot align lockplate and sprocket screw holes, nut may be additionally tightened until screw holes align. 6-34 2002 Buell S3T: Drive/Transmission...
Page 386 15. Adjust drive belt tension. See 1.10 DRIVE BELT 30° DEFLECTION. 16. Fill transmission to proper level with fresh lubricant. See CLUTCH. Line Scribed on Nut and Sprocket Figure 6-62. Aligning Transmission Sprocket 2002 Buell S3T: Drive/Transmission 6-35...
Page 387 HOME NOTES 6-36 2002 Buell S3T: Drive/Transmission...
Page 388 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 390: Specifications
Indicator Lamps on Instrument Support Oil Pressure Indicator 0.15 68024-94 Neutral Indicator 0.15 68024-94 Speedometer Illumination 0.14 67421-99Y Tachometer Illumination 0.14 68073-99Y Instruments Low Fuel Lamp (Tachometer) 0.14 68073-99Y Check Engine Lamp (Tachome- 0.14 68073-99Y ter) 2002 Buell S3T: Electrical...
Page 391 Cable Nut Stator Mounting Screws T-27 TORX with retaining compound, replace after 30-40 in-lbs 3.4-3.5 Nm removal Switchgear Housing Screws metric 25-33 in-lbs 3-4 Nm (Left Side) Switchgear Housing Screws, metric 12-17 in-lbs 1-2 Nm (Right Side) 2002 Buell S3T: Electrical...
Page 392: Ignition System
13. Front Spark Plug Cable 14. Rear Spark Plug Cable 15. Cable Strap 16. Terminal Pin 17. CMP Connector [14] 18. Secondary Lock 19. Ignition Module 20. Washer (2) 21. Screw (2) b0764x7x Figure 7-1. Ignition System Components 2002 Buell S3T: Electrical...
Page 393 This ensures opti- mum engine performance at any altitude or barometric pressure. The O2 sensor input to the ECM is required to ensure a stoichiometric (14.6:1) air/fuel ratio during closed loop operation. 2002 Buell S3T: Electrical...
Page 394: Ignition/Headlamp Key Switch
Disconnect negative battery cable from battery. Detach turn signals and mirrors (metric) to remove front fairing. Figure 7-5 Disconnect ignition key switch connector [33] from main wiring harness. Remove ignition switch face nut. Remove ignition key switch from behind dash panel. 2002 Buell S3T: Electrical...
Page 395 Check ignition key switch for proper operation. If opera- tion fails, reread procedure and verify that all steps were performed. Figure 7-3. Ignition Headlamp Key Switch Connector Install front fairing, mirrors and turn signals. See the appropriate instructions in Section 2. 2002 Buell S3T: Electrical...
Page 396: Ignition Coil
Purge fuel line and remove fuel tank. Figure 7-7 Disconnect the spark plug cables from the coil plug posts (1, 2). Detach connector (7) [83]. Remove two screws and washers to drop coil from frame. 2002 Buell S3T: Electrical...
Page 397 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.35 SEAT. Connect negative battery cable to battery. 2002 Buell S3T: Electrical...
Page 398: Spark Plug Cables
Connect spark plug cables to ignition coil and spark plugs. Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. NOTE 1.17 SPARK PLUGS for spark plug information. 2002 Buell S3T: Electrical...
Page 399: Starter Interlock
Listen for relay “click”. If click is not heard, perform stand retracted or clutch disengaged. ignition system tests. Motorcycle will not start after starter No spark at spark plug. Check for 12 VDC at coil W/BK wire. relay tests. Follow ignition system troubleshooting 7-10 2002 Buell S3T: Electrical...
Page 400 Continuity Infinite ohms To Clutch Switch [95] Figure 7-8. Ohmmeter Diode Test b0644x4x TN/W Ignition Relay TN/GN Diode 1 Polarity Relay Block TN/GN TN/W Diode 2 Polarity Figure 7-9. Diode Polarity Figure 7-10. Diode Wiring 2002 Buell S3T: Electrical 7-11...
Page 401 Diode OK? Check for ground at neutral switch terminal. Ground present? Repair open on TN wire Replace Diode installed Replace between neutral switch neutral backwards. Reverse diode. and Diode 2. switch. polarity. 5062 5061 5064 5063 7-12 2002 Buell S3T: Electrical...
Page 402 [95]. GN wire between Reverse polarity. Ground present? connector [95] and 5072 Diode 2. 5071 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 2002 Buell S3T: Electrical 7-13...
Page 403 HOME Figure 7-11. Starter/Ignition Interlock System 7-14 2002 Buell S3T: Electrical...
Page 404 Replace the assembly with a new switch if necessary. Remove small Phillips screw. Depress clutch lever and hold. Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar. Install new switch. 2002 Buell S3T: Electrical 7-15...
Page 405 (6, 7 and 8) from circuit breaker studs. Remove circuit breaker (3) from circuit breaker clip (1). Install in the reverse order. Ignition Relay Starter Relay Starter Circuit Diode Ignition Circuit Diode Spare Diode Mounting Tabs Figure 7-16. Relay Block 7-16 2002 Buell S3T: Electrical...
Page 406: Diodes
Install tail section and seat. See 2.33 TAIL SECTION. Reconnect negative battery cable to battery. Test interlock for proper operation. 2002 Buell S3T: Electrical 7-17...
Page 407 HOME NOTES 7-18 2002 Buell S3T: Electrical...
Page 408: 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. 2002 Buell S3T: Electrical 7-19...
Page 409 A higher reading indicates excessive current draw. Any accessories must be considered and checked for excessive drain. NOTE A battery with a surface discharge condition could suffer a static drain. Correct by cleaning battery case. 7-20 2002 Buell S3T: Electrical...
Page 410 Accessories on when vehicle is ridden Damaged or Perform CURRENT OUTPUT Fail very slowly for long periods. slipping rotor. TEST. Battery self-discharge and/or acces- sory draw because vehicle was not operated for a long period. Figure 7-19. Charging System Troubleshooting 2002 Buell S3T: Electrical 7-21...
Page 411 HOME b0749chr Main Chassis Ground Main Circuit Breaker Voltage Regulator Starter [46] Battery Figure 7-20. Charging System Circuit 7-22 2002 Buell S3T: Electrical...
Page 412 3.5 amps minimum. d0004x8x If output does not meet speciﬁcations, there may be too many accessories for the charging system to Load Tester handle. Reconnect regulator after testing. Figure 7-22. Check Current Draw (Ignition Switch On) 2002 Buell S3T: Electrical 7-23...
Page 413 Test for resistance with ohmmeter set on the RX1 scale. Resistance across the stator sockets should be 0.2- 0.4 ohms. b0355x7x If the resistance is lower, the stator is damaged and Figure 7-25. Check for Stator Resistance (Typical) must be replaced. 7-24 2002 Buell S3T: Electrical...
Page 414 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 page 5-24. b0356x7x Figure 7-26. Check Stator AC Voltage Output 2002 Buell S3T: Electrical 7-25...
Page 415: Alternator
Loss of torque on TORX fasteners could result in alternator damage. Remove stator wiring grommet (3) from left crankcase half. Withdraw stator wiring (4) from grommet hole in left crankcase half. Remove stator (1). 7-26 2002 Buell S3T: Electrical...
Page 416 11. Test charging system. See 7.8 CHARGING SYSTEM. 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 S3T: Electrical 7-27...
Page 417: Voltage Regulator
Attach new voltage regulator to bracket using screws and washers. Connect voltage regulator connector [46] to alternator stator wiring. Bundle excess wiring in front of oil pump. Secure bundle to oil pump using a new cable strap. 7-28 2002 Buell S3T: Electrical...
Page 418: Battery
7.11 GENERAL Warning Label All 2002 Model Year Buell batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.
Page 419: Battery Charging
See BATTERY TESTING, VOLTMETER TEST, battery has been frozen, overheated or overcharged. on the previous page. If battery needs to be charged, Inspect the battery case for cracks or leaks. proceed to step 2. 7-30 2002 Buell S3T: Electrical...
Page 420 SPORT 12.3 V 3.5 hours 1.75 hours 1 hour 30 minutes 12.0 V 5 hours 2.5 hours 1.5 hours 45 minutes 11.8 V 6 hours, 3 hours, 2 hours 1 hour 40 minutes 20 minutes 2002 Buell S3T: Electrical 7-31...
Page 421 Install the battery on the motorcycle. See BATTERY, INSTALLATION AND CONNECTION. Table 7-6. Battery Load Test COLD CRANKING 100% AMPERAGE (CCA) SPORT 7-32 2002 Buell S3T: Electrical...
Page 422 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.35 SEAT. 2002 Buell S3T: Electrical 7-33...
Page 423: Headlamp
Twist plastic collar (1) counterclockwise to remove. Pull bulb (2) from headlamp housing (3). ASSEMBLY/INSTALLATION NOTE When replacement is required, see your Buell dealer. Not using the speciﬁed bulb may cause charging system prob- lems. CAUTION The bulb contains Halogen gas under pressure. Handle bulb carefully and wear eye protection.
Page 424 (3). Headlamp should ﬂash HIGH beam for as long as the switch is pressed. Turn ignition key switch to OFF. Align headlamp. See 1.22 HEADLAMP. HIGH Beam LOW Beam Passing Lamp Switch Figure 7-39. Passing Lamp Switch 2002 Buell S3T: Electrical 7-35...
Page 425: 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. 7-36 2002 Buell S3T: Electrical...
Page 426: Turn Signals
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. 2002 Buell S3T: Electrical 7-37...
Page 427 Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. Screw (2) Turn Signal Bullet Connectors (2 per Signal) Nut (2) Cable Strap Figure 7-45. Rear Turn Signals 7-38 2002 Buell S3T: Electrical...
Page 428: Turn Signal Flasher
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install tail section and seat. See 2.33 TAIL SECTION. 2002 Buell S3T: Electrical 7-39...
Page 429: Handlebar Switches
[24] along right side frame tube. Detach connector [24] from wiring harness. Cut as many cable straps as necessary to access clutch switch connector [95] along right side frame tube. Detach connector [95] from wiring harness. 7-40 2002 Buell S3T: Electrical...
Page 430 Install seat. See 2.35 SEAT. WARNING WARNING Check all handlebar switches for proper operation before riding motorcycle. Failure to have operating handlebar switches could result in death or serious injury. 2002 Buell S3T: Electrical 7-41...
Page 431: 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 7.5 HANDLEBAR SWITCHES. 7-42 2002 Buell S3T: Electrical...
Page 432: Neutral Indicator Switch
Remove transmission sprocket nut (5) from main drive gear shaft (3). Decrease secondary drive belt tension by loosening axle adjusting nuts. See 1.10 DRIVE BELT DEFLECTION. Remove transmission sprocket (4) (with secondary drive belt) from main drive gear shaft (3). 2002 Buell S3T: Electrical 7-43...
Page 433: Fuses And Circuit Breakers
HOME FUSES AND CIRCUIT BREAKERS GENERAL 6933 Buell motorcycles feature two components which protect the electrical system; fuses and circuit breakers. WARNING WARNING To protect against shock and accidental start-up of vehi- cle, disconnect the negative battery cable before pro- ceeding.
Page 434: Relay Block
To Fuse Block R/BK TN/GN To ECM BK/R GY/O To Side Stand TN/W Switch [60] To Ignition Fuse GY/O TN/W To Right Handle- W/BK bar Switch [22] Ignition Relay Relay Block Figure 7-56. Relay Wiring 2002 Buell S3T: Electrical 7-45...
Page 435: Speedometer
Cut cable straps on wiring harness. Detach wires at plug connector. See Figure 7-61. NOTE Tachometer and speedometer wiring share a common con- 6968 nector on the wiring harness. Nuts and Washers (2) Odometer Reset Button Speedometer Cover Figure 7-59. Dash Panel (Back) 7-46 2002 Buell S3T: Electrical...
Page 436 Figure 7-57. Position dash panel on front fairing bracket. Attach dash panel using three screws and washers (1). Tighten screws to 7-9 ft-lbs (10-12 Nm). Install front fairing by attaching turn signals and mirrors (metric). 2002 Buell S3T: Electrical 7-47...
Page 437: Speedometer Sensor
Install tail section and seat. See 2.33 TAIL SECTION. b0670x2x Speedometer Odometer Reset Sensor LT BE/W Button 3-Place Deutsch A B C Connector [65] Speedometer BK/Y BK/Y Instrument Connector [39] Tachometer Figure 7-63. Speedometer Sensor Wiring 7-48 2002 Buell S3T: Electrical...
Page 438: 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). 2002 Buell S3T: Electrical 7-49...
Page 439 Two Deutsch 3-place socket housings (Part No. 72113- 94BK). ● Deutsch 3-place pin housing (Part No. 72103-94BK). ● Six lengths of 18 gauge wire, each 6.0 in. (15 cm) long. Deutsch Socket Housing (2) Deutsch Pin Housing b05932x7x Figure 7-66. Test Harness 7-50 2002 Buell S3T: Electrical...
Page 440 Go to 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 2002 Buell S3T: Electrical 7-51...
Page 441 Go to ● If necessary, remove speedometer sensor Speedometer Test: and check for accumulation of debris. If Chart debris is not present, replace sensor. If debris is present, clean sensor and repeat test. Replace if necessary. 7-52 2002 Buell S3T: Electrical...
Page 442 6008 plug wires where insulation may be damaged. Does damage exist? Repair as Check speedometer speed necessary. sensor. Clean or replace sen- sor as required. Retest. 6016 Problem solved? System OK. Replace speedometer. 6029 6024 2002 Buell S3T: Electrical 7-53...
Page 443: Tachometer
Cut cable straps on wiring harness. See Figure 7- Detach wires at plug connector. NOTE Tachometer and speedometer wiring share a common con- nector on the wiring harness. Nut and Washer (metric) (2) Tachometer Cover Figure 7-68. Back Dash Panel 7-54 2002 Buell S3T: Electrical...
Page 444 Attach dash panel using three screws and washers (1). Tighten screws to 7-9 ft-lbs (10-12 Nm). Install front fairing by attaching turn signals and mirrors (metric). Figure 7-70. Tachometer Wiring Connector Locations (Approximate) 2002 Buell S3T: Electrical 7-55...
Page 445: Tachometer Performance Check
If testing CEN range, press 4 or 6. Tolerance If testing HI range, press 7 or 9. (+/- RPM) Conversion 33.3 66.7 factor NOTE All tachometer accuracy tolerances were taken at 68°-77° F (20-25° C). 7-56 2002 Buell S3T: Electrical...
Page 446: Clock
Insert bulb housing (4) into clock housing (6). Attach front fairing, mirrors and turn signals. Refer to installation instructions under 2.34 FRONT FAIRING. Red Wire Black Wire Nut and Lockwasher (2) Bulb Housing Mounting Bracket Clock Housing Figure 7-73. Clock Wiring 2002 Buell S3T: Electrical 7-57...
Page 447 HOME NOTES 7-58 2002 Buell S3T: Electrical...
Page 448 [33] HORN YW/BK R/GY TN/GN FLASHER R/BK GY/O TN/GN R GY BK/R R/BK BATTERY STATOR GY/O [30] KEY SWITCH GY/O TN/W TN/W W/BK [62] [61] RELAY FUSE BLOCK BLOCK Figure 7-84. 2001 S3 Wiring Diagram 2002 Buell S3T: Electrical 7-59...
Page 449 Table Of Contents SUBJECT PAGE NO. Appendix A - Tools ..........Appendix B - Electrical Connectors .

Buell 2002 S3T Service Manual

Maintenance 1

Chassis 2

Engine 3

Fuel System 4

Electric Starter 5

Drive/Transmission 6

Electrical 7

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Buell 2002 S3T

Summary of Contents for Buell 2002 S3T