Buell 2002 S3T, Service Manual

Page: 108 / 450

2-34 2002 Buell S3T: Chassis
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CLEANING AND INSPECTION
1. Thoroughly clean and inspect all parts. Replace any
parts that are bent, broken or damaged.
2. See Figure 2-48. Check the slide pipe (17) and outer
tube (8) for score marks, scratches and excessive or
abnormal wear. Replace if worn or damaged.
3. Check the slide bushing (16) and the guide bushing (9)
for excessive wear or scratches. Replace if damaged or
worn.
4. Replace the stopper ring (12) if distorted.
5. Measure spring (7) free length. Replace springs shorter
than service wear limit of 9.13 in. (232 mm).
6. See Figure 2-50. Measure slide pipe runout. Replace
pipe if runout exceeds the service wear limit of 0.008 in.
(0.2 mm).
ASSEMBLY
1. See Figure 2-51. Wrap the end of the slide pipe and the
slide bushing channel with tape to avoid damaging the oil
seal lip when installing.
2. See Figure 2-49. Install a new dust seal (5) and stopper
ring (4) onto the slide pipe.
3. Coat the sealing lips of the new oil seal (3) with fork oil or
sealing grease and install onto the slide pipe with its
marked side facing the dust seal (5). Remove the tape
from the slide pipe end.
4. Install the seal spacer (2), the guide bushing (1) and the
slide bushing (6) onto the slide pipe.
5. Coat the slide bushing (6) and the guide bushing (1) with
fork oil.
CAUTION
The outer tube can move freely up and down on the slide
pipe. Always hold both the slide pipe and outer tube to
prevent damage to bushings and seals.
6. See Figure 2-48. Carefully place the slide pipe (17) into
the outer tube (8).
7. Move and tape or tie the dust seal (13) and stopper ring
(12) out of the way.
8. Using FORK SEAL DRIVER (Part No. B-43721), drive
the guide bushing (9) with the seal spacer (10) and oil
seal (11) into position in the outer tube (4). See
Figure 2-
52.
9. See Figure 2-48. Remove any tape or ties and reinstall
the stopper ring (12) and a new dust seal (13).
10. Clamp the axle holder in a vise with soft jaws or use a
shop towel. Replace the special washer (18) and center
bolt (19) (metric). Tighten the center bolt to 22-29 ft-lbs
(30-39 Nm).
NOTE
The recommended fork oil is hydraulic fork oil Type “E”.
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.
Figure 2-49. Slide Pipe Components
Figure 2-50. Pipe Runout
Figure 2-51. Slide Pipe Protection
1. Guide Bushing
2. Seal Spacer
3. Oil Seal
4. Stopper Ring
5. Dust Seal
6. Slide Bushing
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