Buell 2002 P3, Service Manual

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6-6 2002 Buell P3: Drive/Transmission
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Primary Cover
1. Remove foreign material from magnetic drain plug.
Install plug and tighten to 14-30 ft-lbs (19-54 Nm).
2. Wipe gasket surface clean. Install new gasket on pri-
mary cover.
3. See Figure 6-7. Install primary cover and gasket onto left
crankcase half using mounting bolts.
a. Tighten bolts to 100-120 in-lbs (11-14 Nm) in
sequence shown.
4. See Figure 6-1. Install new shifter lever oil seal.
5. Fit coupling over cable end with rounded side inboard
and the ramp connector button outboard. With retaining
ring side of ramp assembly facing inward, place hook of
ramp around coupling button and rotate assembly coun-
terclockwise until tang on inner ramp fits in slot of pri-
mary cover.
6. Thread nut on adjustment screw until slot of screw is
accessible with a screwdriver. Fit nut hex into recess of
outer ramp and turn adjustment screw counterclockwise.
7. Adjust clutch. See ADJUSTMENT under 6.5 CLUTCH
RELEASE MECHANISM.
8. Adjust primary chain tension. See 6.2 PRIMARY CHAIN .
9. Fill transmission to proper level with fresh lubricant. See
TRANSMISSION FLUID under section 6.4 CLUTCH .
10. Install clutch inspection cover with new gasket and three
TORX screws with washers. Tighten screws in a cross-
wise pattern to 7-9 ft-lbs (10-12 Nm).
11. See Figure 6-1. Install rubber washer and shifter lever
assembly.
a. Tighten pinch screw to 12-14 ft-lbs (16-19 Nm)
12. Install left footpeg support bracket. See 2.21 FOOT-
PEGS AND FOOTPEG SUPPORT BRACKETS .
13. Connect negative battery cable to battery terminal.
Tighten fastener to 60-96 in-lbs (7-11 Nm).
14. Install seat. See 2.28 SEAT .
Figure 6-7. Primary Cover Tightening Sequence
1/4 x 20 x 2 Hex Socket Head (sems) --Qty 14
7667
6 1 7 8
9
11
10
2 13 3 14
4
5
12