Buell 2002 S3T, Service Manual

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2002 Buell S3T: Chassis 2-45
5. On right side of motorcycle, align locator hole with roll
pin and install right rear isolator provided in kit. The right
isolator backing plate has an “R” stamped on it.
6. Turn nut on tool counterclockwise to allow frame to
return to position. Remove tool from between frame and
mount block.
7. Raise frame with hoist to align isolator bolt holes with
threaded holes in bearing adjusting bolts.
8. Mark a horizontal line across the front of each isolator
with a light colored grease pencil or by other non-perma-
nent means.
9. Apply anti-seize to underside of isolator bolt heads.
CAUTION
Use caution when installing isolator bolts. Make sure iso-
lator bolt hole is aligned with threaded hole in bearing
adjusting bolt to avoid cross-threading bolt.
10. See Figure 2-71. Install isolator TORX bolts and washers
through both rubber isolators into bearing adjustment
bolts on each side.
CAUTION
See Figure 2-74. Observe marked line on both rubber iso-
lators after isolator bolts are tightened. If line twists,
apply more LOCTITE ANTI-SEIZE to underside of isolator
bolt heads. Failure to comply will result in damage to
rubber isolators.
11. Tighten right and left isolator bolts to 63-70 ft-lbs (85-
95 Nm).
12. Push rear upper Z bracket bolt until it protrudes from
mount block and install nut. Tighten rear upper Z-bracket
bolt to 22-24 ft-lbs (30-33 Nm).
13. Erase grease pencil marked lines from both isolators.
14. Install front lower and center tie bars to frame with origi-
nal locknuts. Tighten bolts to 30-33 ft-lbs (41-45 Nm).
Install rear tie bar to mount block with lockwasher.
Tighten bolt to 30-33 ft-lbs. (41-45 Nm).
15. Remove hoist from tail section.
16. Install left side rider footpeg. Tighten bolt to 25-30 ft-lbs
(34-41 Nm).
17. See Figure 2-69. Apply LOCTITE THREADLOCKER 243
(Blue) to threads of two sprocket cover to swingarm/drive
support screws and install new sprocket cover to swing-
arm/drive support.
18. See Figure 2-69. Install sprocket cover assembly with
original hardware.
a. Apply LOCTITE THREADLOCKER 243 (blue) to
screw. Install sprocket cover assembly with screw,
washer and spacer. Tighten to 48-72
in-lbs
(5-9 Nm).
b. Apply LOCTITE THREADLOCKER 272 (red) to
swingarm/drive support mounting screws and
install. Tighten screws to 20-25 ft-lbs (27-34 Nm).
c. Install locknut and washer. Tighten to 30-35 ft-lbs
(41-47 Nm).
1 1
WARNING
1
WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
19. Install fuel tank and seat. See 2.35 SEAT and 4.36 FUEL
TANK.
1 1
WARNING
1
WARNING
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion, which could result in death or serious injury.
20. Connect battery cables, positive cable first, to battery ter-
minals.
21. Test ride motorcycle at low speed and check for proper
operation.
Figure 2-74. Isolator Alignment
b0674b2x
Straight Line
(Correct)
Twisted Line
(Incorrect)
Marked
Rear Isolator
Line
OBSERVE MARKED LINE WHILE TIGHTENING