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Buell 2002 S3T, Service Manual

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Buell 2002 S3T Service Manual Download Page 194

3-44

2002 Buell S3T: Engine

HOME

REMOVAL/DISASSEMBLY

1.

See 

Figure 3-59.

  Thoroughly clean area around gear-

case cover (17) and lifters. Blow loose dirt from crank-
case with compressed air.

2.

Remove any parts that will interfere with gearcase disas-
sembly (i.e., exhaust header, air cleaner, etc.).

3.

Remove push rods. See 

3.5 CYLINDER HEAD

.

4.

Remove hydraulic lifters. See 

3.15 HYDRAULIC LIFT-

ERS

.

5.

Check for minimum cam gear end play. Record readings.

6.

Remove cam position sensor and rotor from gearcase
cover. See 

4.30 CAM POSITION SENSOR AND

ROTOR

.

7.

Place a pan under gearcase to collect oil. Remove cover
screws. Carefully remove gearcase cover. Discard old
gasket (9).

NOTE

If cover does not come loose on removal of screws, tap lightly
with a plastic hammer. Never pry cover off.

8.

Remove cam gears (1, 2, 3 and 4). Carefully mark each
component to ensure correct installation.

NOTE

Nut (11) is secured by LOCTITE THREADLOCKER 262 (red)
on the nut threads.

9.

Remove nut (11). Slide pinion gear (5) and oil pump
drive gear (12) off pinion shaft.

CLEANING AND INSPECTION 

1.

Thoroughly clean gearcase compartment, gearcase
cover and gears in solvent to remove oil and carbon
deposits.

2.

Blow out all cover oil passages and bushings with com-
pressed air.

3.

Clean old gasket material from gearcase and cover faces
with cleaning solvent.

Cam and Pinion Gear Identification

See 

Figure 3-60.

  Cam lobes are stamped with the number

“15” followed by a number (1, 2, 3 or 4). The number “15” indi-
cates model year application; the number identifies the cam
location/function.

Bushing Inspection and Removal

1.

See 

Figure 3-59.

 Bushings (7, 8, 13, 14, 15 and 16) are

press fit in gearcase cover (17) and crankcase. Inspect
each bushing against its corresponding cam gear shaft
or pinion gear shaft. See 

Table 3-9.

2.

See 

Figure 3-61.

  Use a BUSHING AND BEARING

PULLER (Part No. HD-95760-69A) to remove bushings
from gearcase cover and crankcase.

Figure 3-60. Cam Identification

Table 3-9. Gear Shaft Specifications

GEAR 

SHAFT

CORRECT 

CLEARANCE

SERVICE WEAR 

LIMIT

Cam

0.0007-0.0022 in.

(0.0178-0.0559 mm)

0.003 in.

(0.076 mm)

Pinion

0.0023-0.0043 in.

(0.0584-0.1092 mm)

0.0050 in.

(0.1270 mm)

Figure 3-61. Removing Bushing

Identify cams by 
stamped number

b0096a3x

15-1 = Rear Exhaust
15-2 = Rear Intake
15-3 = Front Intake
15-4 = Front Exhaust

Bushing and Bearing Puller 
(Part No. HD-95760-69A)

2806a

Summary of Contents for 2002 S3T

Page 1: ...2 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 2: ......

Page 3: ... 41174 Rear Wheel Support Stand and Part No B 41174 2 Replacement Pad Part No B 41177 Front Fork Holding Tool Part No B 41325 99 Scanalyzer Software Cartridge Part No B 42887 Brake Caliper Piston Remover Part No B 43721 Front Fork Seal Driver Part No B 43875 Fork Spring Compressor Part No B 44623 Isolator Tool A ...

Page 4: ...oad Adjustment Tools Part No B 59000A Pro Level Oil Gauge Part No HD 01289 Rim Protectors Part No HD 21000 Tire Spreader Part No HD 23738 Vacuum Pump Part No HD 25070 Robinair Heat Gun Part No HD 26792 Spark Plug Tester Part No HD 28700 Tire Bead Expander ...

Page 5: ...D 33416 Universal Driver Handle Part No HD 33418 Universal Puller Forcing Screw Part No HD 33446A Cylinder Torque Plates and Torque Plate Bolts Part No HD 33446 86 Part No HD 34623B Piston Pin Retaining Ring Installer Remover Part No HD 34643A Shoulderless Valve Guide Seal Installer Part No HD 34723 Valve Guide Hone 8 mm ...

Page 6: ... Installation Tool Part No HD 34736B Valve Spring Compressor Part No HD 34740 Driver Handle and Remover Used with HD 34643A and HD 34731 Part No HD 34751 Nylon Valve Guide Brush Part No HD 34813 Rowe Flywheel Rebuilding Jig Part No HD 34816 Oil Pressure Switch Wrench Part No HD 35102 Wrist Pin Bushing Hone 20 mm ...

Page 7: ...npond bpdk kznh odlbndpob npond bndb n CYLINDER LEAKDOWN TESTER Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pffb odlbndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho knsdl hlno hslnslp pffb odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nl...

Page 8: ... Packard Terminal Crimp Tool Sealed and non sealed connectors Part No HD 38125 7 Packard Terminal Crimp Tool Sealed connectors Part No HD 38125 8 Packard Terminal Crimp Tool Part No HD 38361 Cam Gear Gauge Pin Set 0 108 in 2 74 mm Diameter Part No HD 38362 Sprocket Locking Link Part No HD 38515 A Clutch Spring Compressing Tool and Part No HD 38515 91 Forcing Screw ...

Page 9: ... Part No HD 39301A Steering Head Bearing Race Remover Part No HD 39302 Steering Head Bearing Race Installer Part No HD 39458 Sprocket Shaft Bearing Outer Race Installer Part No HD 39565 Engine Sound Probe Part No HD 39617 Inductive Amp Probe Use with HD 35500A Part No HD 39621 Electrical Terminal Repair Kit T S P O R S T E R 1 3 C C 4 0 ...

Page 10: ...r Part No HD 39782 Cylinder Head Support Part No HD 39786 Cylinder Head Holding Fixture Part No HD 39800 Oil Filter Crusher Small Part No HD 39823 Oil Filter Crusher Large Part No HD 39847 Universal Ratcheting Tap Reamer Handle Part No HD 39932 Steel or HD 39932 CAR Carbide Intake and Exhaust Valve Guide Reamer ...

Page 11: ...l Part No HD 39965 Deutsch Terminal Crimp Tool Part No HD 39969 Ultra Torch UT 100 Part No HD 39978 Fluke 78 Multimeter DVOM Part No HD 39994 Paint Repair Kit Part No HD 41025 Tool Organizational System Part No HD 41137 Hose Clamp Pliers Part No HD 41155 VHS Video Shelf ...

Page 12: ... No HD 41185 Hose Cutting Tool Part No HD 41185 1 Oil Hose Cutter 10 0 150 200 25 0 30 0 350 400 450 500 55 0 600 650 250 100 10 20 30 40 50 60 70 80 90 Part No HD 41321 Sprocket Holding Tool Part No HD 41325 Scanalyzer and Part No HD 41325 99 Cartridge Part No HD 41404 Test Connector Kit Part No HD 41496 Main Drive Gear Seal Installer ...

Page 13: ...p Tool Part No HD 41675 Oil Pressure Sending Unit Wrench Part No HD 42310 Engine Transmission Stand Part No HD 42311 Oil Filter Wrench Part No HD 42320 Piston Pin Remover Installer Part No HD 42322 Piston Support Plate Part No HD 42376 Battery Charging System Load Tester 600 200 Made in USA PP 9606 0001 ...

Page 14: ...Shaft Seal Installer Part No HD 42682 Breakout Box Part No HD 43894 Crankshaft Locking Tool Part No HD 44069 Timken Snap Ring Remover Installer Part No HD 44358 Flywheel Fixture 2000 Models Part No HD 44404 Sprocket Shaft Inner Timken Bearing Remover Part No HD 45206 Sprocket Shaft Seal Spacer Installer ...

Page 15: ...No HD 94800 26A Connecting Rod Bushing Reamers and Pilots Part No HD 94803 67 Rear Intake Camshaft Bushing Reamer Part No HD 94804 57 Rocker Arm Bushing Reamer Part No HD 94812 1 Pinion Shaft Bushing Reamer Use with HD 94812 87 Part No HD 94812 87 Pinion Shaft Reamer Pilot Use with HD 94812 1 Part No HD 95017 61 Large External Retaining Ring Pliers ...

Page 16: ...ing Bearing Puller Tool Set Set includes items 1 7 Items 8 HD 95769 69 9 HD 95770 69 and 10 HD 95771 69 are optional Part No HD 95952 33B Connecting Rod Clamping Tool Part No HD 95970 32D Piston Pin Bushing Tool Part No HD 96215 49 Small Internal Retaining Ring Pliers Part No HD 96295 65D Timing Mark View Plug Use with HD 33813 Part No HD 96333 51C Piston Ring Compressor ...

Page 17: ...art No HD 96710 40B Crankcase Main Bearing Lapping Tool Part No HD 96718 87 Pinion Bearing Outer Race Lapping Kit Part No HD 96740 36 Connecting Rod Lapping Arbor Part No HD 96796 47 Valve Spring Tester Part No HD 96921 52A Oil Pressure Gauge Part No HD 96940 52A Oil Pressure Gauge Adapter Use with HD 96921 52A ...

Page 18: ...Appendix B Wiring HOME Part No HD 97087 65B Hose Clamp Pliers Part No HD 97292 61 Two Claw Puller Part No HD 99500 80 Wheel Truing and Balancing Stand Part No J 5586 Transmission Shaft Retaining Ring Pliers ...

Page 19: ...s Lights 9 place connector 30 Flasher Relay 3 place relay connector 33 Ignition Headlamp Switch 4 place Packard 38 Headlamp 4 place Amp Multilock 39 Speedometer and Tachometer 10 place connector 46 Voltage Regulator Stator 2 place plug 60 Side Stand Switch 2 place Amp Multilock 61 Four 15 Amp Fuses for Clock Odometer Instruments Lights and Accessories and One 20 Amp Fuse for Ignition 5 slot fuse b...

Page 20: ...minals are fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its fully installed position REMOVING INSTALLING PINS 1 See Figure B 1 Remove the secondary locking wedge 7 Use the hooked end of a stiff piece of mechanic s wire or a needle nose pliers whichever is most suitable 2 Gently depress terminal latches inside pin housing 9 and b...

Page 21: ...of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact NOTE Inspect the quality of the core and insulation crimps Distor tion should be minimal Figure B 2 3 pin Locking Wedge Orientation x0014a7x Socket Housing Pin Housing Arrow points to External Latch Figure B 3 Deutsch Crimping Procedure 1 Insert contact through...

Page 22: ...o each terminal 5 See Figure B 5 With the flat edge against the terminal insert the pick Snap On TT600 3 into the cavity until it stops Pivot the end of the pick away from the terminal and gently tug on wire to pull terminal from chamber Do not tug on the wire until the tang is released or the termi nal will be difficult to remove A click is heard if the tang is engaged but then inadvertently rele...

Page 23: ...minal 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 the pin and socket halves the button always being the top of the connector 2 Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber 3 Rotate the hinged secondary lock inward until tabs fully engage latc...

Page 24: ...insulation Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact 6 See Figure B 7 Insp...

Page 25: ...9 4 488 4 527 4 567 4 606 4 645 4 685 4 724 4 764 4 803 4 842 001 002 003 004 005 006 007 008 009 010 1 64 020 030 1 32 040 050 060 1 16 070 080 090 1 1 8 3 16 2 1 4 3 5 16 3 8 4 7 16 1 2 9 16 025 051 076 102 127 152 178 203 229 254 397 508 762 794 1 016 1 270 1 524 1 588 1 778 2 032 2 286 2 540 3 175 4 762 5 080 6 350 7 620 7 938 9 525 10 160 11 112 12 700 14 288 6 5 8 11 16 7 3 4 8 13 16 7 8 9 1...

Page 26: ...AE 5 STEEL 120 000 PSI MEDIUM CARBON HEAT TREAT 14 22 10 19 33 54 78 114 154 257 382 587 SAE 7 STEEL 133 000 PSI MEDIUM CARBON ALLOY 13 25 44 71 110 154 215 360 570 840 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SOCKET SET SCREW 212 000 PSI HIGH CARBON QUENCHED TEMPERED 9 16 30 70 1...

Page 27: ...h 1 22 1 10 Drive Belt Deflection 1 24 1 11 Drive Belt and Sprocket 1 26 1 12 Primary Chain 1 28 1 13 Preload Adjustment 1 29 1 14 Suspension Damping Adjustments 1 30 1 15 Front Fork 1 31 1 16 Steering Head Bearings 1 32 1 17 Spark Plugs 1 33 1 18 Air Cleaner 1 34 1 19 Ignition Timing 1 35 1 20 Handlebars 1 37 1 21 Throttle Cables 1 38 1 22 Headlamp 1 39 1 23 Storage 1 40 1 24 Troubleshooting 1 41...

Page 28: ......

Page 29: ...his section Repair Disassembly Assembly Replace Removal Installation All special tools and torque values are noted at the point of use All required parts or materials can be found in the appropriate PARTS CATALOG Safety Safety is always the most important consideration when per forming any job Be sure you have a complete understanding of the task to be performed Use common sense Use the proper too...

Page 30: ... may result in minor or moder ate injury Wash bearings in a non flammable cleaning solution Knock out packed lubricant inside by tapping the bearing against a wooden block Wash bearings again Cover bearings with clean material after setting them down to dry Coat bearings with clean oil Wrap bearings in clean paper Be sure that the chamfered side of the bearing always faces the shoulder when bearin...

Page 31: ...with the black light leak detector add 1 4 oz 7 4 ml of dye for each 1 quart 0 9 l of fluid in the system being checked TOOL SAFETY Air Tools Always use approved eye protection equipment when performing any task using air operated tools On all power tools use only recommended accessories with proper capacity ratings Do not exceed air pressure ratings of any power tools Bits should be placed agains...

Page 32: ...support the ratchet head when using socket extensions but do not put your hand on the head or you may interfere with the action of its reversing mechanism 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 Sockets Never use hand sockets on power or impact wrenches Select the right size socket for the job Never cock...

Page 33: ...uid in motorcycles that spec ify D O T 4 fluid on the reservoir cap Mixing different types of fluid may adversely affect braking ability and lead to brake failure which could result in death or seri ous injury Use only D O T 4 BRAKE FLUID Part No 99953 99Y FRONT FORK OIL Use only TYPE E FORK OIL Part No 99884 80 FUEL Use a good quality unleaded gasoline 91 pump octane or higher Pump octane is the ...

Page 34: ...ycle upright not on side stand on a level surface Oil level Between upper and lower marks on dipstick Oil capacity with filter change 2 0 quarts 1 89 liters Oil filter Hand tighten filter 1 2 3 4 turn after gasket contacts surface Brake fluid level and condition 1 3 BATTERY I I I I I I I I Fluid type D O T 4 BRAKE FLUID Part No HD 99953 99Y Change D O T 4 BRAKE FLUID fluid every 2 years See 1 3 BA...

Page 35: ... 1 in 22 2 25 4 mm Rear axle nut torque 68 73 ft lbs 90 99 Nm Primary chain 1 12 PRIMARY CHAIN I I I I I I I Chain freeplay with hot engine 1 4 3 8 in 6 4 9 5 mm Chain freeplay with cold engine 3 8 1 2 in 9 5 12 7 mm Inspection screws torque 40 60 in lbs 5 7 Nm Rear shock absorber 1 14 SUSPENSION DAMPING ADJUSTMENTS I I I I I I I Check for bushing wear and loose mounting hardware Steering head bea...

Page 36: ... IL Controls must be smooth and not binding Front brake and clutch hand levers Section 2 L L L L L L L Check for damage and freeplay Engine low and fast idle speed 1 19 IGNITION TIMING I I I I I I I I I I I I I I Regular idle 850 1050 RPM Ignition timing 1 19 IGNITION TIMING TIMING MARK VIEW PLUG Part No HD 96295 65D BREAKOUT BOX Part No HD 42682 HARNESS CONNECTOR TEST KIT Part No HD 41404 I I I I...

Page 37: ... and replace as required Side stand 2 36 SIDE STAND I L L L L L L Rubber isolator mounts engine and exhaust Sections 2 and 3 I I I I I I I Starter interlock system 7 6 STARTER INTERLOCK I I I I I I I I I I I I I Operation of all electrical equipment and switches Section 7 I I I I I I I I I I I I I I I Check tightness of all fasteners except engine head bolts T T T T T T T Road test X X X X X X X X...

Page 38: ...1 10 2002 Buell S3T Maintenance HOME NOTES ...

Page 39: ...attery has set for one to two hours If the voltage reading is 12 8V or above perform the load test described in Section 7 Table 1 4 Battery Electrolyte Antidotes CONTACT SOLUTION External Flush with water Internal Drink large quantities of milk or water fol lowed by milk of magnesia vegetable oil or beaten eggs Call doctor immediately Eyes Flush with water get immediate medical attention Figure 1 ...

Page 40: ...ery for discoloration raised top or a warped or distorted case which might indicate that the battery has been frozen overheated or overcharged 6 Inspect the battery case for cracks or leaks STORAGE 1WARNING 1WARNING Always store batteries where they cannot be reached by children Contact with the battery s sulfuric acid could result in death or serious injury CAUTION The electrolyte in a discharged...

Page 41: ... positive cable red into threaded hole of battery positive terminal Tighten bolt to 60 96 in lbs 7 11 Nm 3 Insert bolt through battery negative cable black into threaded hole of battery negative terminal Tighten bolt to 60 96 in lbs 7 11 Nm 4 Apply a light coat of petroleum jelly or corrosion retar dant material to both battery terminals 5 Install battery strap a Insert tab on right side of batter...

Page 42: ...ipstick Recommended viscosity depends upon ambient temper ature See Table 1 6 If it is necessary to add oil and Har ley Davidson oil is not available use an oil certified for diesel engines Acceptable diesel engine oil designa tions include CE CF CF 4 and CG 4 The preferred vis cosities for the diesel engine oils in descending order are 20W 50 15W 40 and 10W 40 At the first opportu nity see a Buel...

Page 43: ...apter until filter gasket touches crank case surface Apply another 1 2 3 4 turn by hand 1WARNING 1WARNING Make sure no oil gets on tires when changing oil and fil ter If this occurs traction will be adversely affected which may lead to a loss of control which could result in death or serious injury 9 Fill oil tank with an oil from Table 1 6 Total oil capacity is 2 0 quarts 1 89 liters including th...

Page 44: ... tablespoons of salt in a glass of warm water Call a doc tor In case of contact with skin or eyes flush with plenty of water Get medical attention for eyes KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Failure to comply could result in death or serious injury 1WARNING 1WARNING Never mix D O T 4 with other brake fluids such as D O T 5 Use only D O T 4 brake fluid in motorcycles that spec ify D O T ...

Page 45: ...d lower marks on reservoir See Figure 1 12 3 Depress release and then hold brake lever pedal to build up hydraulic pressure 4 Open bleeder valve about 1 2 turn counterclockwise brake fluid will flow from bleeder valve and through tub ing When brake lever pedal has moved 1 2 to 3 4 of its full range of travel close bleeder valve clockwise Allow brake lever pedal to return slowly to its released pos...

Page 46: ...ly 0 84 in 21 3 mm slide rubber boot 1 down over assembly Brake pedal adjustment is not needed b If measurement is not within specification adjust brake pedal NOTE See Figure 1 14 Minimum allowable pushrod thread engage ment inside turn buckle is 0 24 in 6 0 mm 3 Adjust brake pedal a See Figure 1 13 Loosen locknut 3 while holding rod adjuster Move locknut away from top surface of turn buckle b Tur...

Page 47: ...eye clockwise to shorten or counterclockwise to lengthen to factory set tings of 4 75 in 120 7 mm or maximum length of 4 88 in 124 mm 3 Tighten jam nut 4 Apply LOCTITE THREADLOCKER 243 Blue to threads of upper eye fastener 5 Install upper eye to shift rod with upper eye fastener Tighten to 59 66 in lbs 6 6 7 5 Nm 6 Check for proper shift lever clutch operation Table 1 7 Shifter Rod Adjustment SETT...

Page 48: ... rear brake pads using procedure under 2 14 REAR BRAKE CALIPER BRAKE ROTORS Brake Rotor Thickness 1WARNING 1WARNING Do not allow brake fluid bearing grease lubricants etc to contact brake rotor or reduced braking ability will occur which could result in death or serious injury Check brake rotors for minimum thickness At the 500 mile 800 km service interval At every scheduled service interval there...

Page 49: ...uled service interval Check for proper front and rear tire pressures when tires are cold Compare pressure against Table 1 8 WHEEL BEARINGS Check wheel bearings Every time the wheel is removed 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 ...

Page 50: ...Tighten to 14 30 ft lbs 19 41 Nm 5 Remove four TORX screws with washers 1 from clutch inspection cover 2 Remove clutch inspection cover from primary cover Do not damage or dislodge Quad ring from primary cover CAUTION Do not overfill the transmission with fluid Overfilling may cause rough clutch engagement incomplete disen gagement clutch drag and or difficulty in finding neutral at engine idle 6 ...

Page 51: ...ttoms 5 Turn adjusting screw 6 clockwise 1 4 turn Install lock plate 5 and spring 4 on adjusting screw flats If hex on lockplate does not align with recess in outer ramp rotate adjusting screw clockwise until it aligns 6 Squeeze clutch hand lever to maximum limit three times This sets the ball and ramp mechanism Pull outer cable conduit and at the same time adjust cable adjuster to provide 1 16 1 ...

Page 52: ... motorcycle s weight is not compressing the rear shock It is not necessary to raise the rear wheel off the ground to reach this point 4 See Figure 1 23 Apply 10 lbs of force to belt at midpoint of bottom strand using BELT TENSION GAUGE Part No HD 35381 The deflection should be upwards as shown a Deflection measured with 10 lbs of force should be 1 50 1 75 in 38 1 44 5 mm at the bottom strand If de...

Page 53: ...deflection rear wheel alignment loosen locknut hold axle adjuster bolt and turn adjusting nut a If belt is too loose tighten adjusting nut to decrease deflection and therefore increase drive belt tension b If belt is too tight loosen adjusting nut to increase belt deflection and therefore decrease drive belt ten sion c See Figure 1 26 Repeat this step until the distance between the flat on the axl...

Page 54: ...m A knife point will not penetrate the chrome plating 3 Replace rear sprocket if major tooth damage or loss of chrome exists Drive Belt See Figure 1 27 Inspect drive belt for Cuts or unusual wear patterns Outside edge bevelling 8 Some bevelling is common but it indicates that sprockets are misaligned Outside ribbed surface for signs of stone puncture 7 If cracks damage exists near edge of belt rep...

Page 55: ...monitor condition 3 Missing Teeth Replace Belt 5 Fuzzy Edge Cord Not Serious OK to Run but monitor condition 7 Stone Damage Replace Belt if damage is on edge 2 Pac Man Cracks Replace Belt 4 Chipping Not Serious OK to Run but monitor condition 5 Hook Wear Replace Belt 8 Bevel Wear Outboard Edge Only OK to Run but monitor condition ...

Page 56: ...t point in the drive as measured with special ized factory equipment If a chain has less than 1 4 in 6 4 mm vertical freeplay with a cold engine adjust free play to the field specification of 3 8 1 2 in 9 5 12 7 mm The looser specification will avoid overtightening which might otherwise occur during adjustment using non factory equip ment and methods 5 See Figure 1 28 Install O ring 4 6 Fasten ins...

Page 57: ... move the can towards the rear of the motorcycle NOTE All measurements must be taken with rider seated on motorcycle Riders with passenger at or near GVWR may exceed optimum shock length measurement preload adjustment 4 See Figure 1 33 When preload adjustments have been made apply wheel bearing grease halfway around the shock 180 degrees to the mating faces of the locknut and adjuster nut and the ...

Page 58: ... Adjust rebound damping using the slotted dial on the remote reservoir at the front of the shock Compression Damping See Figure 1 35 Adjust compression damping using the slot ted dial on the shaft at the end of the shock Adjusting Rear Shock 1 Using a screwdriver turn the slotted dial on the appropri ate adjuster clockwise until it stops This is the maximum damping setting for that adjustment 2 Tu...

Page 59: ...unt of recommended fork oil into fork pipe 6 Check fork oil level Maximum and minimum oil levels are listed in Table 1 11 a With front fork fully compressed clamp vertically in FRONT FORK HOLDING TOOL Part No B 41177 b Measure distance from fork oil 4 surface to top of outer tube 1 using PRO LEVEL OIL GAUGE Part No B 59000A See Figure 1 37 c Add or drain fork oil as needed until distance from top ...

Page 60: ...t 10 000 miles 16 000 km and every 10 000 miles 16 000 km thereafter lubricate the steering head bearings with WHEEL BEARING GREASE Part No 99855 89 See 2 17 FORK STEM AND BRACKET ASSEMBLY for lubri cation procedure ADJUSTMENT 1 Test motorcycle according to procedure listed under INSPECTION If adjustment is needed follow the instructions below 2 See Figure 1 39 Loosen both pinch screws 7 on lower ...

Page 61: ...ean a hot running engine valves not seating or improper ignition timing The glassy deposit on the spark plug is a conductor when hot and may cause high speed misfiring A plug with eroded electrodes heavy deposits or a cracked insulator must be replaced d A plug with a white yellow tan or rusty brown pow dery deposit indicates balanced combustion Clean off spark plug deposits at regular intervals 4...

Page 62: ...le ment Volatile flammable cleaning agents may cause an intake system fire which could result in death or serious injury 1 Check filter element Hold filter element up to strong light source The element can be considered sufficiently clean if light is uniformly visible through the element 2 Thoroughly clean backplate filter box and inside of cover 3 See Figure 1 44 Place filter element 2 in filter ...

Page 63: ...a Remove the timing plug from the timing inspection hole centered below the cylinders on the right side of the crankcase b Remove the spark plugs c Jack up vehicle to allow rotation of the rear wheel d Shift transmission into fifth gear 4 Bring engine to top dead center TDC a Standing on left side of vehicle slowly rotate rear wheel in a counter clockwise direction until front intake valve opens a...

Page 64: ...ck 9 Remove BREAKOUT BOX harness and connect elec tronic control module connector 11 1WARNING 1WARNING 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 10 Install seat and tail section See 2 33 TAIL SECTION Figure...

Page 65: ...orce or dam age to handlebars might result 1 See Figure 1 50 Loosen clamp screws 1 2 2 Move handlebar to desired position 3 Tighten clamp screws to 10 12 ft lbs 14 16 Nm NOTE First tighten the front clamp screws 1 to 10 12 ft lbs 14 16 Nm Once the front clamp screws are tight tighten the rear clamp screws to 10 12 ft lbs 14 16 Nm 1WARNING 1WARNING Handlebars must not touch front forks or gas tank ...

Page 66: ...52 Turn adjuster on throttle control cable until throttle cam stop 5 touches stop plate Tighten jam nut on throttle control cable adjuster release throttle control grip 7 Turn handlebars fully to right Turn adjuster on idle con trol cable 3 until end of cable housing just touches the cable guide 2 8 See Figure 1 51 Twist and release throttle control grip a few times Throttle plate must return to i...

Page 67: ...right with both tires resting on floor and with front wheel held in straight alignment directly forward 7 Turn ignition switch to IGN Set handlebar headlamp switch to HIGH beam position 8 Check light beam for alignment a The main beam which is a broad flat pattern of light should be centered equally above and below the horizontal line b The main beam of light should also be directed straight ahead...

Page 68: ...DEFLECTION 6 Adjust primary chain See 1 12 PRIMARY CHAIN 7 Check tire inflation See 1 8 TIRES AND WHEELS If the motorcycle will be stored for an extended period of time securely support the motorcycle under the frame so that all weight is off the tires 1WARNING 1WARNING Do not apply any oil to brake rotors or brake pads Oil on brake pads degrades braking efficiency and may cause an accident which ...

Page 69: ... not set properly See dealer 6 O2 IAT or ET sensors damaged or malfunctioning See dealer 7 Ignition coil not functioning 8 Engine oil too heavy winter operation 9 Water or dirt in fuel system clogged fuel filter injector 10 Air leak at intake manifold 11 Valves sticking Starts But Runs Irregularly or Misses 1 Fuel level too low Add gasoline 2 Battery nearly discharged 3 Spark plugs in bad conditio...

Page 70: ...RICAL SYSTEM Alternator Does Not Charge 1 Regulator rectifier module not functioning 2 Rectifier not grounded 3 Engine ground wire loose or broken 4 Loose or broken wires in charging circuit 5 Stator not functioning 6 Rotor not functioning Alternator Charge Rate Is Below Normal 1 Regulator rectifier module not functioning 2 Stator not functioning 3 Rotor not functioning 4 Weak battery 5 Loose conn...

Page 71: ...lbs 65 72 Nm Tighten rear nut to 66 73 ft lbs 90 99 Nm 3 Excessive wheel hub bearing play 4 Rear wheel out of alignment with frame and front wheel 5 Rims and tires out of true sideways tire runout should not be more than 0 080 in 2 03 mm 6 Rims and tires out of round or eccentric with hub tire runout should not be more than 0 090 in 2 29 mm 7 Irregular or peaked front tire tread wear 8 Tire and wh...

Page 72: ...1 44 2002 Buell S3T Maintenance HOME NOTES ...

Page 73: ...rake Line and Switch 2 30 2 16 Front Fork 2 32 2 17 Fork Stem and Bracket Assembly 2 37 2 18 Steering Head Lock 2 38 2 19 Swingarm 2 39 2 20 Rear Isolators 2 43 2 21 Rear Shock Absorber 2 46 2 22 Suspension Theory 2 48 2 23 Suspension Adjustments 2 49 2 24 Throttle Control 2 52 2 25 Clutch Control 2 53 2 26 Handlebars 2 55 2 27 Exhaust System 2 56 2 28 Footrests 2 59 2 29 Sprocket Cover 2 60 2 30 ...

Page 74: ......

Page 75: ...oad Clearance 5 2 13 21 Front Wheel Travel 4 7 11 94 Rear Wheel Travel 4 6 11 68 Trail 3 8 9 65 Rake 24 5 degrees WEIGHTS LBS KG Wet Weight 518 235 GVWR 915 415 GAWR Front 330 150 GAWR Rear 585 265 CAPACITIES U S LITERS Fuel Tank including reserve 5 4 gallons 20 44 Reserve Low Fuel indicator light at 0 4 gallons 1 51 Oil Tank 2 0 quarts 1 89 Transmission 1 0 quart 0 95 TIRE AND POSITION SOLO RIDIN...

Page 76: ...TE THREADLOCKER 243 blue Front Caliper Banjo Bolt 16 20 ft lbs 22 27 Nm Front Caliper Bleeder Valve 3 5 ft lbs 4 7 Nm metric Front Caliper Pad Hanger Pin 11 14 5 ft lbs 15 20 Nm metric Front Caliper Mounting Bolt 22 25 ft lbs 30 34 Nm LOCTITE THREADLOCKER 272 red Front Fairing Mount Bolts 22 25 ft lbs 30 34 Nm Front Fender Lower Mounting Screws 10 15 in lbs 1 2 Nm metric Front Fender Upper Mountin...

Page 77: ...g Screw 12 15 in lbs 1 2 Nm Rear Brake Rotor Screws 35 40 ft lbs 48 54 Nm LOCTITE THREADLOCKER 272 red metric Rear Master Cylinder Banjo Bolt 16 20 ft lbs 22 27 Nm metric Rear Master Cylinder Mounting Screws 8 10 ft lbs 11 14 Nm metric Rear Master Cylinder Rod to Brake Pedal Screw 10 12 ft lbs 14 16 Nm Rear Shock Mounting Screw 30 33 ft lbs 41 45 Nm metric Saddlebag Support Bracket Upper Bolt 13 1...

Page 78: ...he width of the bead seat measured in inches 17 0 is the normal diameter of the rim in inches mea sured at the bead seat diameter DOT means that the rim meets Department of Transpor tation Federal Motor Vehicle Safety Standards See the tables below Table 2 1 Tire Fitment Tubeless Cast Wheels WHEEL SIZE POSITION CONTOUR RIM SIZE RIM VALVE HOLE DIAMETER DUNLOP SPORTMAX II TOURING RADIAL TIRE SIZE 17...

Page 79: ...reviated V I N when ordering parts or making inquiries about your Buell motorcycle Figure 2 1 Abbreviated V I N Location b0304x2x Figure 2 2 2002 Model Year Thunderbolt S3T V I N s 4 MZ RS 11 J 2 3 000001 Varies can be 0 9 or X Sample V I N as it appears on the steering head 4MZFS11J123100001 Sample abbreviated V I N as it appears on the left side crankcase FS112100001 11 World 56 California Manuf...

Page 80: ...53 ft lbs 65 72 Nm Tighten rear axle nut metric to 66 73 ft lbs 90 99 Nm Excessive side play or radial up and down play in wheel hubs Replace wheel hub bearings Alignment of rear wheel in frame or with front wheel Check 1 10 DRIVE BELT DEFLECTION or repair swingarm as described under 2 19 SWINGARM Rims and tires out of true sideways should not be more than 0 080 in 2 03 mm Replace rims See 2 8 TIR...

Page 81: ...s replacement of any tire punctured or damaged 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 In emergency situations if a temporary repair is made ride slowly with as light of a load as possi...

Page 82: ...te injury 2 Inspect all parts for damage or excessive wear 3 Inspect brake rotor a Measure rotor thickness Replace if less than ser vice wear limit See 1 7 BRAKE PADS AND ROTORS b Check rotor surface Replace if warped or badly scored ASSEMBLY 11WARNING 1WARNING Do not allow brake fluid bearing grease lubricants etc to contact brake rotor or reduced braking ability will occur which could result in ...

Page 83: ...e 2 8 Install axle nut a Apply LOCTITE THREADLOCKER 243 blue to axle threads b Install washer 3 and axle nut 4 metric over threaded end of axle c Insert screwdriver or steel rod through hole 1 in axle d While holding axle stationary tighten axle nut 4 metric to 48 53 ft lbs 65 72 Nm 4 Tighten the four front axle pinch screws 2 metric to 13 15 ft lbs 18 20 Nm 5 Install front brake caliper See 2 11 ...

Page 84: ...BEARING PULLER Part No HD 95760 69A and 1 1 8 in COLLET Part No HD 95769 69 2 Remove two bearings from sprocket side of wheel 3 Remove four screws metric to detach rear brake rotor from wheel hub 4 Remove five bolts and washers to detach belt sprocket from wheel hub CLEANING AND INSPECTION 1 Thoroughly clean all parts in solvent 1CAUTION Never use compressed air to spin dry bearings Very high bear...

Page 85: ...tall two bearings Insert bearings separately pressing on outer race only Fully seated bearings will touch shoulder for spacer sleeve b Insert spacer sleeve into wheel hub c On the brake rotor side of the wheel insert bearing into wheel hub until it contacts end of spacer sleeve Press on outer race only 4 Verify that wheel is true See 2 7 CHECKING CAST RIM RUNOUT 5 Install tire if removed Under all...

Page 86: ... 2 4 Rim Radial Runout 1 See Figure 2 10 Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification shown in Table 2 4 Table 2 4 Wheel Runout WHEEL TYPE MAXIMUM LATERAL RUNOUT MAXIMUM RADIAL RUNOUT Cast 0 040 in 1 02 mm 0 ...

Page 87: ... Figure 2 11 Loosen both tire beads from rim flange 11WARNING 1WARNING Do not use excessive force when starting bead over rim Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury 4 If a bead breaker machine is not available attach RIM PROTECTORS Part No HD 01289 to the rim Using tire tools not sharp instruments start upper bead over edg...

Page 88: ... tools working toward valve in both directions 11WARNING 1WARNING Do not inflate tire over 40 psi 275 kPa to seat the beads If the beads fail to seat to 40 psi 275 kPa deflate and relubricate the bead and rim and reinflate to seat the beads but do not exceed 40 psi 275 kPa Inflating the tire beyond 40 psi 275 kPa to seat the beads can cause the tire rim assembly to burst with force sufficient to c...

Page 89: ...nce is 1 0 oz 28 g total weight applied to the front wheel 2 0 oz 56 g total weight applied to the rear wheel Wheels should be balanced to within 1 4 oz 7 g at 60 MPH 97 KM H See Figure 2 16 Use only WHEEL WEIGHTS Part No 43692 94Y which have special self adhesive backings Apply WHEEL WEIGHTS to the flat surface of the wheel rim 1 Make sure that area of application is completely clean dry and free...

Page 90: ...cause irritation of eyes and skin and may be harmful if swallowed If large amount of fluid is swallowed induce vomiting by administering two tablespoons of salt in a glass of warm water Call a doc tor In case of contact with skin or eyes flush with plenty of water Get medical attention for eyes KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Failure to comply could result in death or serious injury ...

Page 91: ...rn pads Loose mounting bolts Warped rotor Replace brake pads Tighten bolts Replace rotor Ineffective brake lever pedal travels to limit Low fluid level Piston cup not functioning Fill master cylinder with approved brake fluid and bleed system Rebuild cylinder Ineffective brake lever pedal travel normal Distorted or glazed rotor Distorted glazed or contaminated brake pads Replace rotor Replace pads...

Page 92: ...r serious injury 2 See Figure 2 18 Remove banjo bolt 6 metric and two banjo washers 4 to disconnect brake line 5 from mas ter cylinder Discard banjo washers 3 Remove screw 10 lockwasher 9 and washer 8 to detach brake lamp switch 7 NOTE The individual parts of the brake lamp switch are not service able Replace switch upon failure 4 Remove two screws 1 metric and clamp 2 to detach master cylinder as...

Page 93: ...housing if any scratches dents or other damage is noted 5 Inspect boot for cuts tears or general deterioration Replace as necessary ASSEMBLY 1 See Figure 2 23 Check piston assembly components a Small end of spring 1 sits behind primary cup 2 Large side of primary cup faces spring b Secondary cup 3 sits within ridge at middle of pis ton 4 2 Insert piston assembly spring first into master cylinder S...

Page 94: ... tion add D O T 4 BRAKE FLUID Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front master cylinder reservoir 11WARNING 1WARNING Always verify proper operation of relief port see Step 6 A plugged or covered relief port can cause brake drag or lockup which may cause loss of vehicle control which could result in death or serious injury 6 Verify proper operation of the master cylinder...

Page 95: ... d Remove brake pads from caliper 4 See Figure 2 25 Detach caliper from mounts a Remove both mounting screws 5 while supporting caliper above brake rotor b Slowly remove caliper by tilting away from wheel and then pulling away from rotor DISASSEMBLY 1 See Figure 2 26 Remove four screws 3 metric to separate caliper halves 2 Remove two O rings from between caliper halves and discard 3 See Figure 2 2...

Page 96: ...for damage or excessive wear Replace both pads as a set if the friction material of either pad is worn to 0 04 in 1 0 mm or less ASSEMBLY 1 See Figure 2 28 Install pistons and O rings a Apply a light coat of D O T 4 BRAKE FLUID to O rings pistons and caliper piston bores b Install two new O rings 6 in grooves of each piston bore c Install pistons 5 in each piston bore 2 Install two new O rings 3 b...

Page 97: ...6 With the master cylinder in a level position verify that the brake fluid level is 1 8 in 3 2 mm from molded boss inside reservoir Add D O T 4 BRAKE FLUID if neces sary 11WARNING 1WARNING Always verify proper operation of relief port see Step 7 A plugged or covered relief port can cause brake drag or lockup which may cause loss of vehicle control which could result in death or serious injury 7 Ve...

Page 98: ...nd will not seal properly over time Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury CAUTION To avoid leakage verify that banjo washers banjo bolt hydraulic brake line and master cylinder bore are com pletely clean 1 See Figure 2 31 Connect brake line to master cylinder using two new banjo washers and banjo bolt metric 2...

Page 99: ... from brake pedal turn buckle 4 a Spin locknut 3 away from top surface of turn buckle b Turn rod adjuster 2 to free rod from turn buckle 4 4 See Figure 2 35 Remove two screws 2 metric to detach master cylinder 3 from frame 5 See Figure 2 36 Detach remote reservoir a Remove top or bottom clamp on hose connected to master cylinder b Remove screw to detach reservoir from frame if nec essary DISASSEMB...

Page 100: ...TION 1 See Figure 2 36 Connect remote reservoir a If removed attach remote reservoir to frame using screw Tighten to 12 15 in lbs 1 2 Nm b Attach line to master cylinder using clamp 2 See Figure 2 35 Attach master cylinder 3 to frame using two screws 2 metric Tighten to 8 10 ft lbs 11 14 Nm 11WARNING 1WARNING Use only copper crush banjo washers See Parts Catalog for Part No with D O T 4 brake flui...

Page 101: ...orking properly 6 Add brake fluid and bleed brake system See 1 5 BRAKES 7 Figure 2 36 With motorcycle in a level position check that brake fluid is between the upper and lower marks on reservoir Add D O T 4 BRAKE FLUID if necessary Be sure gasket and cap on reservoir fit securely 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle see Step 8 Visibility is a major conc...

Page 102: ...components using denatured alco hol Do not use mineral base cleaning solvents such as gasoline or paint thinner Use of mineral base solvents causes deterioration of rubber parts that continues after assembly This could result in improper brake operation which could result in death or serious injury 1 Clean all parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contaminate with mineral oil ...

Page 103: ...NING Use only copper crush banjo washers See Parts Catalog for Part No with D O T 4 brake fluid Earlier silver banjo washers are not compatible with D O T 4 fluid and will not seal properly over time Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury 11WARNING 1WARNING Any leak in brake system will adversely affect brake o...

Page 104: ...ARNING If rear brake line must be replaced use only the brake line with the olive drab coating on the metal portion of the line See Parts Catalog for Part No with DOT 4 brake systems The previous black metal brake line is NOT compatible with DOT 4 brake fluid Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury 1 See Figure ...

Page 105: ...Nm 7 See Figure 2 43 Connect brake line 1 to caliper with two new banjo washers 2 and banjo bolt 1 metric Tighten to 16 20 ft lbs 22 27 Nm 8 See Figure 2 42 Install brake lamp switch 4 a Coat brake lamp switch threads with LOCTITE PIPE SEALANT WITH TEFLON and install to tee nut of brake line Tighten to 7 8 ft lbs 10 11 Nm b Install wires on terminals 2 3 9 Install bleeder valve if removed Refill m...

Page 106: ...om the outer tube and slightly compress the fork leg Remove the fork bolt with attached O ring 2 2 See Figure 2 47 Set the FRONT FORK SPRING COM PRESSOR Part No B 43875 1 onto the spring collar 2 Push down on the collar and remove the spring seat stopper 3 3 See Figure 2 48 Remove the spring collar 4 the spring joint 5 and the spring 6 4 Remove the fork oil by pumping the fork leg and rod 8 10 tim...

Page 107: ...at Stopper 4 Spring Collar 5 Spring Joint 6 O Ring 7 Spring 8 Outer Tube 9 Guide Bushing 10 Seal Spacer 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 8 9 10 11 12 13 7 16 18 19 20 b0652x2x 17 14 15 ...

Page 108: ...uide 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 st...

Page 109: ... PRESSOR Part No B 43875 1 into position and press down on the spring collar 2 18 Set the spring seat stopper 3 between the spring collar 2 and the locknut Remove the FRONT FORK SPRING COMPRESSOR 19 See Figure 2 46 Apply oil to a new O ring and install it into position on the fork bolt Install fork bolt Tighten to 22 29 ft lbs 30 39 Nm 20 Tighten rebound adjuster against the fork bolt 21 Set rebou...

Page 110: ...ubes so that top of each slider tube is flush with the top surface of upper triple clamp and cap protrudes slightly Be sure that top surface of fork is not below top surface of upper triple clamp b Tighten large screws to 18 20 ft lbs 24 27 Nm c Tighten small screw to 10 12 ft lbs 14 16 Nm if loosened during fork stem service 4 Install front fender See 2 31 FRONT FENDER 5 Install front wheel See 2...

Page 111: ...m age Replace if necessary ASSEMBLY INSTALLATION 1 See Figure 2 56 If removed install new bearing cups 5 into frame steering head using STEERING HEAD BEARING RACE INSTALLER Part No HD 39302 2 Liberally coat the bearing cones 4 with grease using WHEEL BEARING PACKER TOOL Part No HD 33067 Work the grease into the rollers 3 Install lower bearing a Place lower bearing dust shield 3 over fork stem b Fi...

Page 112: ...e Figure 2 59 Dished area of steering head lock faces front wheel b Lift front wheel upward c See Figure 2 58 Lock must be in the unlocked posi tion to install Insert lock with key openings posi tioned as shown d Release front wheel 2 See Figure 2 57 Tighten fork stem bolt and triple clamp screws Check bearing adjustment See 2 17 FORK STEM AND BRACKET ASSEMBLY 3 Install and adjust handlebars See 1...

Page 113: ...y 3 Disconnect both battery cables negative cable first 4 Remove seat and attach lifting straps to motorcycle a Insert lifting straps under frame tubes It is not nec essary to remove tail section 5 Attach lifting straps to a floor hoist placed behind the lift Raise motorcycle off lift until rear suspension is unloaded 6 Remove mounting bolt attaching swingarm to rear shock 7 See Figure 2 60 Remove...

Page 114: ... on the right side first NOTE Ledge on tool should engage top of mount block See Figure 2 72 21 After removing both bearing adjustment bolts remove swingarm INSTALLATION 1 See Figure 2 63 Align new swingarm between posts on swingarm mount block 5 2 Insert left threaded and right bearing adjustment bolts 2 3 into swingarm until flush with mount block surface 3 Tighten left side swingarm pinch screw...

Page 115: ...LATORS 10 Attach rear tie bar to swingarm mount block Tighten to 30 33 ft lbs 41 45 Nm 11 Remove scissors jack from under crankcase 12 Install rear shock bolt metric Tighten to 30 33 ft lbs 41 45 Nm 13 Attach feed and drain lines to oil tank and frame Install filter and fill motorcycle with proper oil a Use 2 0 quarts 1 89 liters 14 Attach rear brake pedal to master cylinder pushrod 15 Attach left...

Page 116: ...ARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 20 Attach both battery cables positive cable first 21 Remove motorcycle from lift 22 Compress suspension to install rear fender and lower belt guard 23 Check oil level after...

Page 117: ...side of the swingarm drive support Retain screws NOTE See Figure 2 70 Route strap under frame rails with tail sec tion installed Make sure strap is in V formed by frame rails to prevent rearward movement and that it does not pinch wir ing harness vent lines or cables 6 See Figure 2 70 Strap tail section of frame to overhead beam or hoist and put slight tension on strap to secure frame assembly 7 S...

Page 118: ...n in Protect frame with a shop rag when using pliers See Figure 2 73 Measure isolator roll pin protrusion on both left and right isolator mounts with calipers or metal rule Roll pin should not protrude more than 0 120 in 3 mm If roll pin protrudes more than 0 120 in 3 mm file or grind until within specification 0 080 0 120 in 2 032 3 048 mm Use care when filing to avoid creating sharp edges INSTAL...

Page 119: ... 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 cove...

Page 120: ...en screw metric and locknut from the rear mount Discard locknut 8 Remove shock absorber assembly INSTALLATION 1 See Figure 2 76 Place new bushings into mounting holes of shock absorber if only replacing bushings 2 See Figure 2 75 Loosely install rear allen screw metric and new locknut 3 Loosely install front allen screw metric and new lock nut 4 Install rear clamp over front oil pump fitting 5 Sli...

Page 121: ...sis 2 47 Figure 2 76 Rear Shock Absorber b0918x2x Rear Reservoir Clamp Front Reservoir Clamp Nylon 40 45 ft lbs 54 61 Nm Front Shock Mount Reservoir Mount Block Metal Locknut 2 30 33 ft lbs 41 45 Nm Washers 3 Locknut 2 Washers ...

Page 122: ... must be in good con dition and properly inflated Riding on worn or under inflated tires could result in death or serious injury See Figure 2 77 See Figure 2 78 The rear suspension adjusts for compression and rebound damping and spring preload See Figure 2 79 The front suspension adjusts for compres sion and rebound damping If the rear preload adjustment is correct and you have the rebound and com...

Page 123: ...d of the shock Factory setting full damping minus 2 5 turns Adjusting Rear Shock 1 Using a screwdriver turn the slotted dial on the appropri ate adjuster clockwise until it stops This is the maximum damping setting for that adjustment 2 Then turn the dial counterclockwise the recommended amount to align the reference marks This is the factory recommended setting fRONT FORK DAMPING ADJUSTMENTS See ...

Page 124: ...N Pumping on the Rear occurs when you are accelerating out of a corner This problems occurs in two varieties 1 The first type has a movement with a long stroke and a high frequency 2 The second version has a movement with a short stroke and high frequency 1 The shock is too soft Increase compression damping If the adjuster is already set to the max imum add more preload to the spring one turn maxi...

Page 125: ...ed for the rider s size and weight For information on setting rear shock preload see 1 13 PRELOAD ADJUSTMENT DATE FRONT FORK REBOUND FRONT FORK COMPRESSION REAR SHOCK REBOUND REAR SHOCK COMPRESSION RESULTS Max damping minus 0 5 turn Max damping minus 1 75 turns Max damping minus 1 turn Max damping minus 2 5 turns Factory recommended settings ...

Page 126: ...l cable 3 has a smaller fitting end and is posi tioned inside the rear housing 9 2 Run cables inside grooves of each housing 5 9 3 Attach ferrules 7 to cable wheel 8 When properly assembled notches for ferrules will be at 12 o clock 4 Position housings on right handlebar by engaging locat ing pin 10 on front housing with hole in handlebar Attach housings with two screws 1 6 installing longer screw...

Page 127: ...Remove O ring 8 from cable end fitting Clutch Hand Control 1 See Figure 2 84 Detach clutch switch 7 a Remove screw 8 b Depress clutch lever and hold c Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar NOTE The individual parts of the clutch switch are not serviceable Replace switch upon failure 2 Remove bolt 2 metric and nut 6 metric 3 Remove han...

Page 128: ...e 1 9 CLUTCH Clutch Hand Control 1 See Figure 2 84 Attach clutch clamp 5 as follows a Slide clamp over handlebar b Install left switchgear housing See 7 5 HANDLE BAR SWITCHES c Place clamp next to switchgear housing Fasten to handlebar with screw 4 metric Tighten to 30 35 in lbs 3 4 Nm d Install a new left handgrip See 2 26 HANDLE BARS 2 Connect end of clutch cable upper section to clutch han dlev...

Page 129: ...r and in front of fork tube 4 and handlebar clamp 3 b Route left hand control wires 2 under handlebar and in front of fork tube 4 and handlebar clamp 3 c See Figure 2 86 Tighten both front screws 1 to 10 12 ft lbs 14 16 Nm d Then tighten both rear screws 2 10 12 ft lbs 14 16 Nm 4 Install left switch housing See 7 5 HANDLEBAR SWITCHES 5 Install a new left handgrip a Clean end of handlebar with M600...

Page 130: ...torcycle with jack b Remove bolts locknuts and washers c Remove nuts and washers securing front muffler support to voltage regulator bracket and crankcase d Remove header support mount Exhaust Header 1 Remove muffler 2 See Figure 2 91 Loosen the four exhaust header nuts 20 using SNAP ON SWIVEL SOCKET Part No PFSX916 3 Disconnect oxygen sensor at connector 137 4 See Figure 2 92 Remove exhaust heade...

Page 131: ...8 Bolt Washers 2 Metal Locknut Metal Bolts 2 Washer 2 Z Bracket Muffler Voltage Regulator Voltage Regulator Mounting Bracket Header Support Mount Bolts 2 Rear Muffler Mount Bracket Mount Tabs Locknuts 2 Spacer 20 22 ft lbs 27 30 Nm 22 24 ft lbs 30 33 Nm 22 24 ft lbs 30 33 Nm 30 33 ft lbs 41 45 Nm ...

Page 132: ...d locknuts Tighten to 22 24 ft lbs 30 33 Nm 7 See Figure 2 89 Secure muffler to header support mount with bolt locknut and washers Tighten to 22 24 ft lbs 30 33 Nm 8 When only the muffler is being replaced tighten muffler clamp to 40 45 ft lbs 54 61 Nm If also installing the exhaust header leave muffler clamp loose Exhaust Header NOTE Muffler hardware must be tightened before tightening exhaust he...

Page 133: ...ly LOCTITE THREADLOCKER 243 blue to footrest bolts 2 b Install passenger footrests with allen bolts 2 and locknuts 1 Tighten to 24 30 ft lbs 33 41 Nm 2 If removed install footrest mounts 5 a Slide thrust washer 6 shift brake pedal and bush ing 8 on footrest mount b Apply LOCTITE THREADLOCKER 272 red to bolt 10 c Install footrest mount assembly using bolt 10 and washer 9 Tighten to 10 15 ft lbs 14 ...

Page 134: ... LOCTITE THREADLOCKER 243 blue to both screws c Install screws Tighten to 12 17 in lbs 1 2 Nm 2 Apply LOCTITE THREADLOCKER 243 blue to forward screw Install sprocket cover assembly with screw washer and spacer Tighten to 48 72 in lbs 5 9 Nm 3 Apply LOCTITE THREADLOCKER 272 red to two swingarm drive support screws and install Tighten screws to 20 25 ft lbs 27 34 Nm 4 See Figure 2 96 Place fairing l...

Page 135: ...o swing arm 2 Remove lower belt guard 3 stone guard 4 and well nuts 5 from swing arm INSTALLATION 1 See Figure 2 97 Position stone guard 4 with wellnuts 5 and lower belt guard 3 on swing arm 2 Secure with two screws 1 and washers 2 Figure 2 97 Stone Guard b0612x2x 1 Screw 2 2 Washer 2 3 Lower Belt Guard 4 Stone Guard 5 Wellnut 2 1 4 3 2 5 ...

Page 136: ...ide retaining loop points outward and back Install screw 1 through assembly but do not tighten at this time 2 Place washer and spacer 3 around speedometer cable guide 6 The guide retaining loop points outward and back Install screw 5 through assembly but do not tighten at this time 3 Install lower mounting screws 7 metric Plastic washer fits between fork leg and back of fender Tighten to 10 15 in ...

Page 137: ... Figure 2 100 Position fender over tire making sure that the brake hose is on the outside of the fender as shown 2 See Figure 2 99 Secure clamp with screw 8 and washer 9 3 Have someone sit on the motorcycle to compress the motorcycle s suspension 4 Apply LOCTITE THREADLOCKER 243 blue to all screws a Install screw 5 and washer 6 into wellnut 7 b Install screws 1 and washers 2 into wellnuts 4 Figure...

Page 138: ...s 5 6 from seat strike plate 4 7 Lift fuel tank and withdraw tail section from frame Glove Box and License Plate Holder 1 Remove tail section 2 Unplug tail lamp brake light connections and remove tail lamp mount See 7 2 TAIL LAMP 3 Remove rear turn signals See 7 3 TURN SIGNALS 4 See Figure 2 102 Remove bolts washers and nuts 1 holding glove box 2 to license plate holder 3 and frame 5 Lift and remo...

Page 139: ...r serious injury 7 Turn ignition key switch to IGN Apply rear brake pedal to test brake lamp operation Turn ignition key switch to LOCK 11WARNING 1WARNING 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 8 Install...

Page 140: ...ng Mount 1 Remove front fairing 2 Remove dash panel and gauges See 2 26 HANDLE BARS 3 Detach headlamp connector from bulb See 7 1 HEAD LAMP NOTE If replacing front fairing mount remove headlamp 4 Cut all cable straps holding wiring to front fairing mount Note routing of wires before removing wires from mount 5 See Figure 2 106 Remove two locknuts 1 washers 2 and bolts 3 to detach front fairing mou...

Page 141: ...g mount 4 Install dash panel and both gauges See 2 26 HANDLE BARS 5 Install front fairing Front Fairing 1 See Figure 2 105 Attach windshield to front fairing using six screws and washers 1 2 Align front fairing on front fairing mount Loosely install both mirrors 5 using two nuts metric on each 3 Install front turn signals 7 See 7 3 TURN SIGNALS 4 Tighten both nuts metric on mirrors to 7 10 in lbs ...

Page 142: ...TALLATION Seat 1 See Figure 2 112 Install seat by sliding metal locating tab 2 on bottom of seat under frame tab 3 2 Press down on seat until seat release lever clicks 11WARNING 1WARNING 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 d...

Page 143: ...nstall seat and test as described Seat Release 1 See Figure 2 111 Place bushing 5 on top of seat latch lever 4 2 See Figure 2 114 Place washer 3 and spring 2 under seat latch lever 4 3 Hook edge of spring 2 over seat latch lever 4 Small loop of spring will rest against frame as shown 4 Align seat release assembly under tail section Secure with shoulder bolt 1 Shoulder bolt must not compress washer...

Page 144: ...from frame 4 Remove bumper 3 from frame 5 Remove screw 2 and side stand dragger 1 INSPECTION 1 Replace dragger when worn to wear line shown in Figure 2 117 2 Test the side stand in the following manner Without vehi cle weight resting on it side stand should move freely into extended down and retracted up positions 3 Check sidestand switch starter interlock for proper operation after the first 500 ...

Page 145: ...onding tab 2 on saddlebag body hinge OPERATION 1 See Figure 2 118 Place ignition key in saddlebag lock 2 Turn key 1 4 turn 2 Lift saddlebag latch CAUTION Do not rest items on an open saddlebag cover Placing objects on an open saddlebag cover could damage cover and mounting hardware CAUTION Make sure contents do not interfere with cover seal when closing If seal is disturbed bags will not close pro...

Page 146: ...3 Install saddlebag liner Close cover by aligning hooks on saddlebag cover with openings on saddlebag body and firmly pushing inward Do not force saddlebag covers closed 4 Lock saddlebag and remove key 5 See Figure 2 121 If saddlebags are difficult to close or install check rear saddlebag bracket alignment on both sides a Slide rubber boot away from bumper assembly b Turn bumper 2 counterclockwise...

Page 147: ...acket Left Side 1 Lift fuel tank and insert fairing lower lip over frame tube 2 See Figure 2 123 Align clamp with metal bracket on fair ing lower Place nylon washer between clamp and metal bracket Insert screw through clamp nylon washer metal bracket and opposite side of clamp Fasten with locknut 3 Tighten fuel tank screw to 18 23 ft lbs 24 31 Nm Wait five minutes and tighten again to 18 23 ft lbs...

Page 148: ...HOME 2 74 2002 Buell S3T Chassis NOTES ...

Page 149: ...3 6 Cylinder and Piston 3 24 3 7 Lubrication System 3 31 3 8 Oil Hose Routing 3 32 3 9 Oil Tank 3 33 3 10 Oil Pressure Indicator Switch 3 34 3 11 Crankcase Breathing System 3 35 3 12 Oiling System Color Foldout 3 36 3 13 Oil Pump 3 37 3 14 Oil Filter Mount 3 40 3 15 Hydraulic Lifters 3 41 3 16 Gearcase Cover and Cam Gears 3 43 3 17 Crankcase 3 50 Table Of Contents ...

Page 150: ......

Page 151: ...ke 28 BTDC 48 ABDC Exhaust 52 BBDC 24 ATDC ENGINE IGNITION SPECIFICATIONS Type Sequential non waste spark Regular Idle 850 1050 RPM Spark Plug Size 12 mm Spark Plug Type Harley Davidson No 10R12 Spark Plug Gap 0 038 0 043 in 0 97 1 09 mm Spark Plug Torque 11 18 ft lbs 15 24 Nm ITEM NEW COMPONENTS SERVICE WEAR LIMITS VALVE Fit in guide Exhaust 0 0015 0 0033 in 0 0381 0 0838 mm 0 0040 in 0 1016 mm I...

Page 152: ...321 mm 0 065 in 1 651 mm Compression ring side clearance Top 0 0020 0 0045 in 0 0508 0 1143 mm 0 0065 in 0 1651 mm 2nd 0 0016 0 0041 in 0 0406 0 1041 mm 0 0065 in 0 1651 mm Oil control ring side clearance 0 0016 0 0076 in 0 0406 0 1930 mm 0 0094 in 0 2388 mm Pin fit loose at room temperature 0 00005 0 00045 in 0 00127 0 01143 mm 0 00100 in 0 02540 mm CYLINDER HEAD Valve guide in head tight 0 0033 ...

Page 153: ...mm GEARCASE Cam gear shaft in bushing loose 0 0007 0 0022 in 0 0178 0 0559 mm 0 003 in 0 076 mm Cam gear shaft end play min except rear intake 0 005 0 024 in 0 127 0 610 mm 0 025 in 0 635 mm Rear intake cam gear shaft end play min 0 006 0 024 in 0 152 0 610 mm 0 040 in 1 016 mm FLYWHEEL Runout Flywheels at rim 0 000 0 010 in 0 000 0 254 mm 0 010 in 0 254 mm Shaft at flywheel end 0 000 0 002 in 0 0...

Page 154: ...ers LOCTITE THREADLOCKER 271 red Isolator Bolt Front 100 110 ft lbs 136 149 Nm Isolator TORX Bolts Rear 63 70 ft lbs 85 95 Nm LOCTITE THREADLOCKER 262 red LOCTITE ANTI SEIZE under bolt heads Oil Filter Adapter 8 12 ft lbs 11 16 Nm LOCTITE THREADLOCKER 243 blue Oil Pressure Signal Light Switch 50 70 in lbs 6 8 Nm Oil Pump Cover Screws 70 80 in lbs 7 9 9 Nm Oil Pump Mounting Screws 125 150 in lbs 14...

Page 155: ... Some fuel suppliers sell gasoline alcohol blends as a fuel The type and amount of alcohol added to the fuel is important DO NOT USE GASOLINES CONTAINING METHANOL Using gasoline methanol blends will result in starting and driveability deterioration and damage to critical fuel sys tem components ETHANOL is a mixture of 10 ethanol Grain alcohol and 90 unleaded gasoline Gasoline ethanol blends can be...

Page 156: ...e process of elimination to indicate any one of the above components is worn it is best to give attention to all of the cylinder head and cylinder parts Compression Test Procedure Combustion chamber leakage can result in unsatisfactory engine performance A compression test can help determine the source of cylinder leakage Use CYLINDER COMPRES SION GAUGE Part No HD 33223 1 A proper compression test...

Page 157: ...lock the rear brake 7 Following the manufacturer s instructions perform a cyl inder leakage test on the front cylinder Make a note of the percent leakdown Any cylinder with 12 leakdown or more requires further attention 8 Listen for air leaks at carburetor intake exhaust head gasket and timing inspection hole See Table 3 2 NOTE If air is escaping through valves check push rod length 9 Repeat proce...

Page 158: ... removed See 3 5 CYLINDER HEAD ENGINE CRANKCASE REPLACEMENT OR COMPLETE ENGINE REMOVAL 1 Perform the steps listed above 2 Remove tail section See 2 33 TAIL SECTION 3 See Figure 3 1 Place a floor hoist behind the lift Attach straps to frame and hoist Raise hoist until straps tighten 4 Detach clutch cable from handlebar lever 5 Remove rear fender and lower belt guard See 2 32 REAR FENDER 6 Remove sp...

Page 159: ...bber isolators align with a frame mounted metal pin 21 Raise frame and walk forward over and away from the engine 22 If necessary remove rear swingarm See 2 19 SWING ARM 23 If necessary detach swingarm mount block from power train by removing bolts 3 4 washers and locknuts Figure 3 2 Supporting the Engine b0251x3x Crating Strap Figure 3 3 Rear Tie Bar Assembly Figure 3 4 Front Tie Bar Assembly 1 G...

Page 160: ...e Secure with nut and washer Tighten to 30 33 ft lbs 41 45 Nm 11 See Figure 3 3 Tighten the two rear isolator TORX bolts to 63 70 ft lbs 85 95 Nm 12 See Figure 3 4 Tighten front isolator bolt 6 to 100 110 ft lbs 136 149 Nm 13 Connect feed return and vent lines to oil tank See 3 8 OIL HOSE ROUTING Use new hose clamps 14 Attach battery ground strap to swingarm mount block 15 Attach clutch cable to h...

Page 161: ...y Connect battery cables positive cable first 8 Install left and right fairing lowers See 2 38 FAIRING LOWERS 9 Install tail section fuel tank and seat See 2 33 TAIL SECTION 10 If engine crankcase installation was performed a Adjust rear belt deflection See 1 10 DRIVE BELT DEFLECTION b Adjust rear shock spring preload See 1 13 PRE LOAD ADJUSTMENT c Adjust clutch lever See 1 9 CLUTCH d Check rear b...

Page 162: ...aining two rocker arm retaining bolts 13 5 Remove lower rocker cover 18 NOTE Remove lower rocker boxes as an assembly then disassem ble as required 6 Mark the location and orientation top bottom of each push rod Remove push rods CAUTION Mark rocker arm shafts for reassembly in their original positions Valve train components must be reinstalled in their original positions to prevent accelerated wea...

Page 163: ...screws are loose Remove head screws 12 See Figure 3 9 Remove cylinder head 18 head gasket 4 and O rings 14 NOTE Front cylinder must be removed through upper triangular frame members with front isolator mount attached 13 See Figure 3 11 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 Figure 3 6 Removing Rocke...

Page 164: ...rew Long 2 2 Head Screw Short 2 3 Arrow Piston Direction 4 Head Gasket 5 Inner Valve Spring 2 6 Outer Valve Spring 2 7 Valve Keeper 4 8 Upper Collar 2 9 Lower Collar 2 10 Valve 1 Intake 1 Exhaust 11 Valve Stem Seal 2 12 Cylinder Stud 4 13 Base Gasket 14 O Ring 2 15 Insert Dowel 2 16 Valve Guide 2 17 Valve Seat 2 18 Cylinder Head 19 Cylinder 20 Piston xlhcylhead ...

Page 165: ...valve stem at the keeper groove 4 Mark valve to ensure that it will be reassembled in the same head Remove valve 10 valve stem seal 11 and lower collar 9 5 Repeat the above procedure for the other valve 6 Disassemble the other head using the same procedure Figure 3 10 Valve Spring Compressor Part No HD 34736B 5694 Valve Spring Compressor Figure 3 11 Middle Valve Train Components Quantities per Eng...

Page 166: ...ocker arm at pad end and push rod end for uneven wear or pitting Replace rocker arm if either condition exists 5 Measure and record rocker arm shaft diameter a Where shaft fits in lower rocker arm cover See Figure 3 12 b Where rocker arm bushings ride See Figure 3 13 6 Measure and record rocker arm shaft bore diameter a In lower rocker cover See Figure 3 14 b Rocker arm bushing inner diameter See ...

Page 167: ...ken or discolored coils 17 See Figure 3 16 Check free length and compression force of each spring Compare with SERVICE WEAR LIMITS If spring length is shorter than specification or if spring compression force is below specification replace spring 18 Examine push rods particularly the ball ends Replace any rods that are bent worn discolored or broken 19 See Figure 3 17 Check head gasket surface on ...

Page 168: ...nt the correct guide height has been reached 5 Ream guides to final size or within 0 0010 in 0 0254 mm of final size using VALVE GUIDE REAMER Steel Part No HD 39932 or Carbide Part No HD 39932 CAR Use REAMER LUBRICANT Part No HD 39964 or liberal amounts of suitable cutting oil to pre vent reamer chatter 6 Apply the proper surface finish to the valve guide bores using the VALVE GUIDE HONE Part No H...

Page 169: ...sitioned 2 3 of the way toward the outside edge of face 4 If valve seat pattern is too close to the stem side of valve face cut 60 angle in order to raise seat If pattern is too close to the edge of valve face cut 31 angle in order to lower seat 5 After cutting either or both 31 or 60 angles to position seat final cut 46 or grind 45 seat angle to obtain proper 0 040 0 062 in 1 016 1 575 mm width 6...

Page 170: ...ry light pressure against valve head d Rotate lapping tool and valve alternately clockwise and counterclockwise a few times 2 Lift valve and rotate it about 1 3 of a turn clockwise Repeat lapping procedure in Step 1 3 Repeat Step 2 Then remove valve 4 Wash valve face and seat Dry parts with a new clean cloth or towel 5 Inspect valve and seat a If inspection shows an unbroken lapped finish of uni f...

Page 171: ...er collar 4 8 See Figure 3 9 Install valve springs 5 6 and upper col lar 8 9 Compress springs with VALVE SPRING COMPRESSOR Part No HD 34736B 10 Insert valve keepers 7 into upper collar 8 making sure they engage groove in valve stem The keeper gaps should be equal 11 Release and remove VALVE SPRING COMPRESSOR 12 Repeat Steps 4 11 for the remaining valve s 11WARNING 1WARNING Always wear proper eye p...

Page 172: ...ng numerical sequence i e 1 2 3 and 4 a Tighten each screw to 8 10 ft lbs 11 14 Nm b Tighten each screw to 13 15 ft lbs 18 20 Nm c See Figure 3 27 Mark cylinder head and head screw shoulder with a line as shown View A Tighten each screw a 1 4 turn 85 90 View B 12 See Figure 3 11 Rotate engine so that both lifters 6 from the cylinder being serviced will be installed on the base circle lowest positi...

Page 173: ...7 Nm NOTES Tubular frame prohibits direct access to bolt 12 on right rear cylinder Use TORQUE ADAPTOR SNAP ON Part No FRDH 181 and TORQUE COMPUTER SNAP ON Part No SS 306G to correctly assemble 20 See Figure 3 5 Install middle and upper rocker covers a Place a new gasket 7 on lower rocker box assem bly b Install middle rocker cover 5 with umbrella valve next to intake manifold c Place a new gasket ...

Page 174: ...ength of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the pistons 11WARNING 1WARNING The piston pin retaining rings are highly compressed in the ring groove and may fly out with considerable force when pried out of the groove Always wear safety glasses or goggles while removing or installing retaining rings Failure to comply could result in death...

Page 175: ...175 in 0 03175 0 04445 mm clearance in bushing b If piston pin to bushing clearance exceeds 0 00200 in 0 05080 mm replace worn parts See CON NECTING ROD BUSHING on page 3 29 6 Clean piston pin retaining ring grooves 7 Examine piston and cylinder for cracks burnt spots grooves and gouges 8 Check connecting rod for up and down play in lower bearings When up and down play is detected lower bearing sh...

Page 176: ...adings 4 Repeat measurement at center and then at bottom of ring path Record readings This process will determine if cylinder is out of round or egged and will also show any cylinder taper or bulge 5 See Table 3 6 If cylinder is not scuffed or scored and is within service limit see FITTING CYLINDER TO PIS TON on page 3 27 NOTE If piston clearance exceeds service limit cylinders should be rebored a...

Page 177: ...torque plates attached All honing must be done from the bottom crankcase end of the cylinder Work for a 60 crosshatch pattern Fitting Piston Rings NOTE Ring sets and pistons 0 040 in 1 016 mm oversize are not available on 1203cc engines See Figure 3 33 Piston rings are of two types compression 1 2 and oil control 3 The two compression rings are posi tioned in the two upper piston ring grooves The ...

Page 178: ...ll second compression ring with dot towards top 3 See Figure 3 36 Install rings so end gaps of adjacent rings are a minimum of 90 apart Ring gaps are not to be within 10 of the thrust face centerline 4 See Figure 3 37 Check for proper side clearance with thickness gauge as shown See 3 1 SPECIFICATIONS for tolerance NOTE If the ring grooves are clean and the side play is still not cor rect replace ...

Page 179: ...river must be attached facing the opposite direction as it was for removal of the bushing 8 Clean up and size bushing to 0 0010 0 0005 in 0 0254 0 0127 mm undersize using REAMER Part No HD 94800 26A Sizing bushing with less than 0 00125 in 0 03175 mm clearance can result in a bushing loosening and or seized pin in rod 9 Hone bushing to final size using WRIST PIN BUSHING HONE Part No HD 35102 Use a...

Page 180: ...sing PISTON PIN RETAINING RING INSTALLER 2 Part No HD 34623B Place new retaining ring on tool with gap pointing up See Figure 3 41 NOTE Make sure the ring groove is clean Ring must be fully seated in the groove with the gap away from the slot at the bottom 5 See Figure 3 36 Make sure the piston ring end gaps are properly positioned as shown 6 Remove PISTON SUPPORT PLATE 7 Lubricate cylinder wall p...

Page 181: ...xide along with other gases and particu lates When first starting and warming an engine some of the water vapor that gets into the engine crankcase condenses to form liquid water If the engine is driven long enough to thor oughly warm the crankcase most of this liquid water is again vaporized and exhausted through the crankcase breather system A moderately driven vehicle making short runs may not ...

Page 182: ...ses The hoses continue on beneath the engine and forward to the oil pump The feed hose 1 attaches to the rear most oil pump fitting the return hose 3 connects forward and above After diverging from the feed and return hoses the vent hose is routed beneath the starter It continues on to the right side of the motorcycle See Figure 3 45 Here the vent hose 1 connects to an elbow fitting 3 on the gearc...

Page 183: ...ts Loosely install bolts and lockwashers 1 at all four mounting points NOTE Starting at the top mounting points will simplify installation 2 Connect the four oil tank hoses Tighten new clamps 5 8 and 10 using HOSE CLAMP PLIERS Part No HD 41137 NOTE Worm clamp 3 may be reused on feed hose 4 3 Fill oil tank See 1 4 ENGINE LUBRICATION SYSTEM 4 Install rear fender See 2 32 REAR FENDER 11WARNING 1WARNI...

Page 184: ...system As the engine warms to normal operating temperature the engine oil will warm up and become less viscous oil pressure decreases When an engine is operated at high speeds the volume of oil circulated through the oiling system increases resulting in higher oil pressure As engine speed is reduced the volume of oil pumped is also reduced resulting in lower oil pressure To check oil pressure use ...

Page 185: ...from the crankcase air collects and passes through a small drain hole 2 where it eventually returns to the crankcase The crankcase air is routed through a passage in each cylin der head The air then travels through each air cleaner breather bolt 4 Hoses leading from the air cleaner bolts vent the air to the air cleaner s snorkel Figure 3 49 Crankcase Breathing System Typical Cylinder 1 Push Rod Co...

Page 186: ...Oil also enters an intersecting passage in the gearcase cover Oil flow is then routed to the crankshaft area 10 Oil enters a hole in the end of the pinion gear shaft and travels to the right flywheel where it is routed through the flywheel to the crankpin Oil is forced through the crank pin to properly lubricate the rod bearing assembly 11 Oil flows up passages in the push rods to the rocker arm s...

Page 187: ...e 3 52 Gravity fed oil from the oil tank enters the pump through the feed hose connector 5 It is forced by the gerotor feed set 7 through a hose to the oil filter Return oil from the flywheel compartment is drawn back into the pump and is forced by the gerotor scavenge set 9 back to the oil tank See INTERNAL ENGINE PASSAGES for oil passages within the engine The oil pump seldom needs servicing Bef...

Page 188: ...ver 6 off body 12 Remove and discard O ring 14 7 Slide both pieces of gerotor feed set 7 separator plate 8 and both pieces of gerotor scavenge set 9 off gear shaft 11 8 Remove and discard retaining ring 16 Remove thrust washer 15 and gear shaft 11 Figure 3 51 Oil Pump Hardware 3 2 1 1 4 5 1 Mounting Screw and Washer 2 long 2 Cover Screw and Washer 2 short 3 Feed Hose Connection 4 Return Hose Conne...

Page 189: ...4 Position gerotor separator plate into case and line up slots on perimeter with tabs inside oil pump body 5 Place gerotor feed set 7 over gear shaft 11 6 Install a new O ring 14 into groove in cover 6 Place cover onto pump body Install T27 TORX cover screws 2 with washers 3 Tighten to 70 80 in lbs 7 9 9 Nm 7 Place new mounting gasket 10 in position NOTE Use new hose clamps If fittings were remove...

Page 190: ...ssed air ASSEMBLY NOTE Use TEFLON PIPE SEALANT or HYLOMAR on all fittings installed to oil filter mount 1 Install oil pressure indicator switch 6 using OIL PRES SURE SENDING UNIT WRENCH Part No HD 41675 Tighten to 5 7 ft lbs 7 10 Nm NOTE The filter adapter 1 has identical ends either end may be installed into the filter mount 4 2 Apply LOCTITE THREADLOCKER 243 blue to the threads on that end of th...

Page 191: ...head 3 See Figure 3 58 Remove both push rod covers 4 a Remove screw 8 and washer 10 b Lift retainer 6 and seal 7 upward a few inches on push rod cover 4 c Push upward on push rod cover while pulling bottom of cover clear of crankcase Remove cover 4 Remove both hydraulic lifters 3 a Remove two anti rotation screws with washers 2 b Remove lifters 3 from crankcase bore using a thin bladed screwdriver...

Page 192: ...7 Nm 5 Install push rod covers a Slide new seal 5 and retainer 6 over top of push rod cover 4 b Position new O ring 7 at top of push rod cover c Hold cover at an angle and insert top through hole in cylinder head Push up on cover while aligning bot tom of cover with lifter bore in crankcase d Lower retainer 6 with seal 5 onto crankcase aligning locating pin 11 with hole in retainer e Insert screw ...

Page 193: ...nging one component can affect many others It is important to know and understand all inspection procedures and how components interact Figure 3 59 Gearcase and Valve Train Components 1 Rear Exhaust Cam Gear 2 Rear Intake Cam Gear 3 Front Intake Cam Gear 4 Front Exhaust Cam Gear 5 Pinion Gear 6 Seal 7 Front Intake Cam Gear Bushing 8 Front Exhaust Cam Gear Bushing 9 Gearcase Cover Gasket 10 Right C...

Page 194: ...clean gearcase compartment gearcase cover and gears in solvent to remove oil and carbon deposits 2 Blow out all cover oil passages and bushings with com pressed air 3 Clean old gasket material from gearcase and cover faces with cleaning solvent Cam and Pinion Gear Identification See Figure 3 60 Cam lobes are stamped with the number 15 followed by a number 1 2 3 or 4 The number 15 indi cates model ...

Page 195: ...e gearcase cover bore 2 After you install a new bushing in gearcase cover line ream the bushing to correct size See BUSHING REAM ING REAR INTAKE CAM GEAR BUSHING IN GEARCASE COVER 1 See Figure 3 59 Rear intake cam gear bushing 15 must be installed in its gearcase cover 17 bore using an arbor press You will need to orient the bushing in a specific position of rotation within the cover bore and will...

Page 196: ...reamed to size first After reaming any bushing check shaft fit in the bushing It may be necessary to make a second pass with reamer to attain proper fit CAM GEAR BUSHINGS IN RIGHT CRANKCASE HALF 1 Separate two halves of crankcase if not already accom plished Place right crankcase half on flat surface with gearcase side upward Bushing to be reamed must be oriented as shown in Figure 3 64 2 See Figu...

Page 197: ...ntify the previously reamed rear intake cam gear bushing 13 in right crankcase half 10 which has been disassembled from left crankcase half Insert the shank end of REAR INTAKE CAMSHAFT BUSHING REAMER Part No HD 94803 67 through gearcase side of this bushing 3 With reamer inserted into bushing in right crankcase half attach gearcase cover to right crankcase half securing with a minimum of three mou...

Page 198: ...inion shaft Tighten nut to 35 45 ft lbs 48 61 Nm 3 Liberally apply engine oil to bushings shafts and gears Install all cam gears into bushings of right crankcase half properly aligning timing marks of cam gears and pinion gear See Figure 3 62 NOTE Because of the larger diameter additional gear which meshes with the pinion gear on the outboard end of the rear intake 15 2 cam gear the rear exhaust 1...

Page 199: ... gap between bushing in crankcase half and cam gear shaft thrust face shoulder using a feeler gauge This is cam gear end play d Compare cam gear end play measurements with the SERVICE WEAR LIMITS Make repairs as required if end play does not meet specifications 7 Install hydraulic lifters and push rods See 3 15 HYDRAULIC LIFTERS 8 Install cam position sensor and rotor in gearcase cover See 4 30 CA...

Page 200: ...ccurate flywheel end play reading preload sprocket shaft bearings Create a suitable tool by weld ing two handles to an old engine sprocket nut Install the nut and sprocket Tighten to 190 210 ft lbs 258 285 Nm 5 Check flywheel end play a Rotate and push on sprocket shaft while reading dial indicator b Then rotate and pull on sprocket shaft while reading dial indicator c Replace bearing inner shim S...

Page 201: ...over and primary drive clutch compo nents See Primary Chain Drive under 6 5 PRIMARY DRIVE CLUTCH 6 Remove starter motor See 5 7 STARTER 7 Remove transmission See 6 7 TRANSMISSION CASE 8 See Figure 3 73 Remove screws and rear engine mount bolt securing crankcase halves together 9 Position crankcase on work bench gearcase side up Tap crankcase with plastic mallet to loosen top half and separate the ...

Page 202: ...s 11 Gearshaft bearing will remain on flywheel pinion shaft Remove retaining ring and bearing may be slipped off pinion shaft 12 See Figure 3 76 Place flywheel assembly in FLYWHEEL FIXTURE Part No HD 44358 Pull sprocket shaft bear ing with SPROCKET SHAFT INNER TIMKIN BEARING REMOVER Part No HD 44404 and ALL PURPOSE CLAW PULLER Part No HD 95635 46 using bolts in place of jaws Insert a penny or suit...

Page 203: ...on the retaining ring e See Figure 3 79 Inserting the tips of a large retain ing ring pliers Snap On PR 56A into one hole in each claw compress the retaining ring and remove it from the crankcase bore f Loosen allen head screws and remove claws from retaining ring Figure 3 76 Removing Sprocket Shaft Inner Timken Bearing Typical Figure 3 77 Sprocket Shaft Outer Race Removal 8203 1 1 All Purpose Cla...

Page 204: ...ass visual check and have no apparent wear the same set may be reinstalled Make certain all parts of bearing are installed in exactly the same order in which they were removed If any part of bearing assembly is worn entire assembly should be replaced Fitting Pinion Bearings See Figure 3 75 A pressed in bushing in the right crankcase half is the outer race The inner race is pressed on the pinion sh...

Page 205: ...tory as shown See Figure 3 82 Outer races are identified at the factory as shown NOTE The different sizes of crankcase sets and flywheel assem blies will not have separate part numbers That is a replace ment crankcase set may have a class 1 2 or 3 pinion outer race Replacement flywheel assemblies will have either a class A or B inner race See Figure 3 85 Pinion bearings are identified as shown Fig...

Page 206: ...n with left case bearing and to meet the following specifications See LAPPING ENGINE MAIN BEARING RACES ID 1 5646 1 5652 in 39 7408 39 7561 mm Roundness within 0 0002 in 0 0051 mm Taper within 0 0002 in 0 0051 mm Surface finish 16 RMS 7 See Figure 3 83 Pull inner race from pinion shaft using TWO CLAW PULLER Part No HD 97292 61 CENTER CAP Part No HD 95652 43A and BEARING SEPARA TOR SNAP ON TOOLS St...

Page 207: ...ition where hole is larger at ends than it is in the center 4 Withdraw arbor far enough to coat lightly with 220 grit lapping compound Do not apply a heavy coat Reposi tion lap in bushing and turn handle at moderate hand speed Work lap back and forth in bushing as it is revolved to avoid grooving and tapering At frequent intervals remove lap from crankcase wash and inspect bushing Lapping is compl...

Page 208: ...ue White Gray Green 1 5656 1 5658 in 39 766 39 771 mm Red Blue White Gray Green 1 5654 1 5656 in 39 761 39 766 mm Red Blue White Gray Green 1 5652 1 5654 in 39 756 39 761 mm Red Blue White Gray Green 3 1 5650 1 5652 in 39 751 39 756 mm Red Blue White Gray Green 2 1 5648 1 5650 in 39 746 39 751 mm Blue White Gray Green 1 1 5646 1 5648 in 39 741 39 746 mm White Gray Green INNER RACE OD In 1 2496 1 2...

Page 209: ...earings into left crankcase half 6 Always install left outer race 4 prior to installing right outer race 5 because the installer base 1 is usable only when you follow this sequence of race installation 2 Insert SPORTSTER end of installer base 1 into inboard side of left crankcase half 6 bearing bore until base contacts installed retaining ring 3 3 Position left outer race 4 over bearing bore on ou...

Page 210: ...clockwise until bearing firmly con tacts inner spacer Inner and outer bearings must be tight against inner spacer for correct bearing clear ance Remove tool from sprocket shaft f Spin crankcase half to verify that flywheel assembly is free 10 See Figure 3 92 Install new spacer in seal ID With the open lipped side facing outward center seal spacer assembly over bearing bore CAUTION Do not remove th...

Page 211: ...eaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 15 Install pistons and cylinders See 3 6 CYLINDER AND PISTON 16 Install oil pump See 3 13 OIL PUMP 17 Install cam gears gearcase cover lifter guides and lift ers See 3 16 GEARCASE COVER AND CAM GEARS 18 Install cylinder heads See 3 5 CYLINDER HEAD 19 Install starter See 5 7 STARTER 20 Install transmi...

Page 212: ...3 62 2002 Buell S3T Engine HOME NOTES ...

Page 213: ...2002 Buell S3T Engine 3 63 RETURN OIL FEED OIL RETURN OIL FEED OIL INTERNAL ENGINE PASSAGES ...

Page 214: ...ks But Will Not Start 4 26 4 13 No ECM Power 4 31 4 14 Fuel Pressure Test 4 34 4 15 Idle Speed Control 4 39 4 16 Misfire 4 40 4 17 Trouble Code 11 44 4 18 Trouble Code 13 48 4 19 Trouble Code 14 53 4 20 Trouble Code 15 57 4 21 Trouble Code 16 61 4 22 Trouble Codes 23 and 32 65 4 23 Trouble Codes 24 and 25 69 4 24 Trouble Code 33 72 4 25 Trouble Code 35 75 4 26 Trouble Code 44 78 4 27 Trouble Codes...

Page 215: ... Air Temperature Sensor 94 4 35 Throttle Position Sensor 95 4 36 Fuel Tank 96 4 37 Fuel Tank Vent Valve 99 4 38 Inline Fuel Filter 101 4 39 Fuel Pump 102 4 40 Throttle Body and Intake Manifold 104 4 41 Air Cleaner 108 4 42 Evaporative Emissions Control 110 SUBJECT PAGE NO ...

Page 216: ...8 11 Nm Cylinder Head Breather Bolts 10 15 ft lbs 14 20 Nm HYLOMAR Fuel Cap Flange Screws 22 25 in lbs 2 5 2 8 Nm special pattern to tighten Fuel Pump Stud Nuts 68 75 in lbs 8 9 Nm LOCTITE THREADLOCKER 243 blue Fuel Supply Valve Screws 25 27 in lbs 2 8 3 1 Nm Fuel Tank Mounting Bolt 18 23 ft lbs then wait 5 min and retighten to 18 23 ft lbs 24 31 Nm special procedure Ignition Bracket Screw 25 30 f...

Page 217: ...oop system which allows it to adjust for all possible operating con ditions High lift cams make it necessary for an open loop system at idle and at wide open throttle During open loop operation the system utilizes programmed fuel and spark maps in the ECM which provide stable idle and ease of cold starting and maximum power at wide open throttle WOT During closed loop operation the system relies o...

Page 218: ...ch IGN Circuit Breaker Cam Sensor TP Sensor IAT Sensor Main Circuit Breaker Battery ET Sensor O2 Sensor Fuel Pump Front Injector Rear Injector Check Engine Lamp Tach Bank Angle Sensor Dual Coil Front Rear Ground Scanalyzer PC Development Electronic Control Module one 12 place black connector 10 one 12 place gray connector 11 WIRE COLOR CODES USED IN THIS DOCUMENT LT Light GY Gray V Violet BK Black...

Page 219: ...also be starting or performance problems RESOLVING PROBLEMS To resolve system problems five basic steps are involved In order of occurrence they are 1 Check for trouble codes by observing check engine lamp See 4 4 CHECKING FOR TROUBLE CODES 2 Retrieve trouble codes using SCANALYZER Part No HD 41325 or check engine lamp diagnostics See 4 5 SCANALYZER 4 6 CHECK ENGINE LAMP DIAGNOS TICS and Figure 4 ...

Page 220: ...s currently detected by the ECM b The lamp stays off for only four seconds and then comes back on for an eight second period This indi cates a functional error code is stored but no cur rent trouble code exists c If the lamp remains on beyond the eight second period then a current trouble code exists 3 See CODE TYPES for a complete description of trouble code formats NOTE Trouble codes relating to...

Page 221: ...ECM trouble codes 52 through 55 or with the camshaft sensor timing trouble code 56 RETRIEVING TROUBLE CODES The fuel injection system provides two levels of diagnostics The most sophisticated mode employs a portable diag nostic tool called a Scanalyzer This device plugs into the motorcycle wiring harness It facilitates the diagnosis of system problems through a direct interface with the ECM See 4 ...

Page 222: ...CANA LYZER Part No HD 41325 and DIAGNOSTIC CARTRIDGE Part No B 41325 99 are available proceed as follows 1 Turn ignition light key switch OFF 2 See Figure 4 6 Remove the seat See 2 35 SEAT 3 Remove rubber protective plug from data link connector Plug Scanalyzer into connector If necessary detach connector from frame 4 Turn ignition light key switch ON Set engine stop switch to RUN but do not start...

Page 223: ...ront Coil 5 Rear Coil 6 Tachometer DIAGNOSTIC MENU 1 System ID 2 Trouble Codes 3 Data Monitor 4 Active Diagnostic 5 Special Tests 6 Tool Setup 7 Calibrations MODE MODE MODE MODE MODE MODE 1 2 3 4 5 6 Main Menu Secondary Menus DATA MONITOR MENU 7 CALIBRATION MENU 1 TPS Zero Function 2 AFV Reset MODE RPM 0 ADVANCE F 0 0 DEG ADVANCE R 0 0 DEG ET 14 F ET 4 98 V IAT 76 F IAT 3 75 V O2 0 00 V A F RATIO ...

Page 224: ... return to the trouble codes menu 3 Press the mode key again to return to the diagnostic menu In this manner regardless of where the operator is in the program the mode key need only be pressed once or twice to return to the main menu 4 After correcting system problems clear trouble codes using the trouble codes menu of the scanalyzer Clearing Codes Unlike the check engine lamp diagnostics note th...

Page 225: ...ble code The length of time the lamp is illuminated and the length of time in which it is off are each about 1 second in duration 5 The second digit follows a Following transmission of the first digit there is another 2 second pause in which the lamp is off b The lamp will then flash one or more times to indi cate the second digit of the trouble code Count the number of times the lamp flashes to r...

Page 226: ... and run when the trouble codes are received using a jumper wire on Pins 1 and 2 of the data link connector However if the jumper wire is removed with the engine running the check engine lamp will continue to flash trouble codes To stop check engine lamp from flashing codes turn engine stop switch OFF CLEARING CODES After correcting system problems clear trouble codes If the Scanalyzer is not avai...

Page 227: ...ector 11 a Attach gray connector from Breakout Box to corre sponding gray ECM connector b Attach gray connector from the wiring harness to gray connector on Breakout Box REMOVAL 1 See Figure 4 14 Depress latches on each side of con nectors 10 black and 11 gray 2 Detach Breakout Box connectors from ECM connectors 3 Detach Breakout Box connectors from wiring harness 4 Reattach ECM connectors to wiri...

Page 228: ...ister on the DVOM Using Scanalyzer Part No HD 41325 1 Connect Scanalyzer to vehicle See 4 5 SCANALYZER 2 Start motorcycle engine and run at idle 3 Enter wiggle test mode a Press 5 from the DIAGNOSTIC MENU to enter the SPECIAL TESTS menu b Press 1 from the SPECIAL TESTS menu to enter the WIGGLE TEST 4 Shake or wiggle harness to detect intermittents If inter mittents are present the Scanalyzer will ...

Page 229: ...TICS General Information The diagnostic check is an organized approach to identifying a problem caused by an electronic control system malfunc tion 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 Diagnostic Tips If the Scanalyzer is not working properly ...

Page 230: ...il 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 Table 4 3 Engine Performance Problems SYMPTOM SOLUTION Engine temperature circuit 4 19 TROUBLE CODE 14 CMP circuit 4 28 TROUBLE CODE 56 Spark plugs and or wires 4 16 MISFIRE Improper fuel pressure 4 14 FUEL PRESSURE TEST Improper TP sensor adjustment...

Page 231: ... 16 Battery Voltage 4 21 TROUBLE CODE 16 page 4 61 23 Front Fuel Injector 4 22 TROUBLE CODES 23 AND 32 page 4 65 24 Front Ignition Coil 4 23 TROUBLE CODES 24 AND 25 page 4 69 25 Rear Ignition Coil 4 23 TROUBLE CODES 24 AND 25 page 4 69 32 Rear Fuel Injector 4 22 TROUBLE CODES 23 AND 32 page 4 65 33 Fuel Pump 4 24 TROUBLE CODE 33 page 4 72 35 Tachometer 4 25 TROUBLE CODE 35 page 4 75 44 Bank Angle ...

Page 232: ...top Switch 22 TN W Ignition relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 Lt GN R V R Data Link 91A Lt GN R V R BK GY GY Table 4 6 Wire Harness Connectors in Figure 4 16 NO 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 Deu...

Page 233: ...LL NOT START NO YES NO Are any trouble codes displayed YES Compare scan data with Table 4 1 Are values normal or within typical ranges NO Refer to applicable trouble code flow chart Start with lowest trouble code All diagnostic codes are listed in Table 4 5 YES Go to Diagnostic Check Part 2 of 2 YES See 4 8 WIGGLE TEST If Wiggle Test does not recreate condition refer to symptoms tables NO Refer to...

Page 234: ...nk connector terminals against their ECM connector pins for continuity Continuity present in all four circumstances DATA LINK TERMINAL ECM TERMINAL Pin Wire Color Pin Connector 1 Lt GN R 11 11B 2 BK 11 10B 3 V R 12 11B 4 GY 1 10B NO Repair short to ground YES Check Scanalyzer on another vehicle Scanalyzer OK YES Inspect terminals for damage or repair opens as necessary NO YES Scanalyzer malfunctio...

Page 235: ...RNESS CONNECTOR TEST KIT Part No HD 41404 black pin probe and patch cord 2 See Figure 4 18 Inspect connector 10 black for con tamination or corrosion If connection is good replace ECM See 4 29 ELECTRONIC CONTROL MODULE 3 Check continuity between instrument connector 39 Pin 8 and ECM connector 10 black Pin 4 a Gain access to tachometer cover by removing fair ing b Remove tachometer cover and pull c...

Page 236: ...gine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 Instruments 39 Tachometer O BK Y Check Engine Lamp O BK Y BK Y GY Table 4 7 Wire Harness Connectors in Figure 4 20 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 39 Main harness to instruments 10 place Multiloc...

Page 237: ... to 4 13 NO ECM POWER NO Refer to 4 12 ENGINE CRANKS BUT WILL NOT START for no start condition and then return to 4 10 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON to resolve no engine check lamp YES NO Disconnect instruments connector 39 Remove BK Y wire from connector 39 and ground it Reconnect connector 39 Check engine lamp ON YES Repair open or short to voltage on BK Y wire between connector 3...

Page 238: ...seconds It may then come back on for an eight second period for a stored error or remain on continuously current error DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 11 flow chart 1 See Figure 4 22 If the lamp goes off when the black ECM connector 10 is unplugged the BK Y wire is not shorted to ground Figure 4 21 Check Engine Lamp Figure ...

Page 239: ...gine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 Instruments 39 Tachometer O BK Y Check Engine Lamp BK Y BK Y GY O Table 4 8 Wire Harness Connectors in Figure 4 23 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 39 Main harness to instruments 10 place Multiloc...

Page 240: ...N YES NO Check engine lamp function OK Check for trouble codes See 4 4 CHECKING FOR TROUBLE CODES With ignition key switch OFF reconnect black ECM connector 10 With ignition key switch ON verify that there is NOT a 4 second lamp OFF period Is there a lamp OFF period YES NO Repair short to ground on BK Y wire between connector 39 and connector 10 Repair short to ground on BK Y wire between connecto...

Page 241: ...r look for spark Repeat proce dure on other spark plug cable 11WARNING 1WARNING The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gas before removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could r...

Page 242: ...ion Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker b0527x4x Fuel Pump Ignition Coil 83 BN Y BN Y GN W BK W R W Electronic Control Module ECM Connector 10 Connector 11 GY GY TN GN TN W TN W Clutch Switch 95 Side Stand Switch 60 Neutral Switch GY Cam Position Sensor 14 A B C GN W R W Y BE Y BE GY BE O BE O BK W C B A b0617x4x LTGN GY BK GY Bank Angle Sensor 134...

Page 243: ...seconds and check engine lamp illuminate NO No pump response but light OK See 4 14 FUEL PRESSURE TEST NO Pump OK but no light See 4 10 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON YES Install Fuel Pressure Gauge See 4 14 FUEL PRES SURE TEST While cranking engine for more than two seconds to ensure proper system operation verify that pressure rises to 46 53 PSI 317 365 kPa Adequate pressure NO Inco...

Page 244: ...e resistance See 4 16 MISFIRE Check coil by substituting one known to be good OR Check coil resistance See 7 X IGNITION COIL YES Connect Breakout Box Check continuity between ignition coil Terminal A of connec tor 83 and Breakout Box BK Pin 7 Measure resistance between ignition coil Terminal C and ECM Pin 6 10B Resistance should be less than 1 0 ohm Is it NO Disconnect cam position sensor connecto...

Page 245: ...le CMP sensor and wires to identify any loose connects engine misfires or stalls Any found YES Pinion gear key failure loose rotor cup or other mechanical failure NO Replace cam position sensor See Section 7 NO Repair YES NO Disconnect connector 14 Measure resis tance between Terminal B and Connector 14B and Breakout Box GY Pin 3 Is resistance greater than 1 0 ohms Remove cam timer cover using 1 8...

Page 246: ...the side stand switch See Figure 4 28 By disengaging the clutch and grounding the relay through the clutch switch See Figure 4 29 If the ECM does not appear to be receiving power check the ground sources A blown ignition fuse can also disable the ECM DIA GNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 13 flow chart 1 Connect BREAKOUT BOX Part...

Page 247: ...ndlebar Switch 22 TN W TN W Main Chassis Ground Diode 1 Diode 2 Neutral Switch Side Stand Switch 60 W BK W BK ECM 10 Pin 1 also provides power to fuel pump both fuel injectors coil and bank angle sensor Table 4 10 Wire Harness Connectors in Figure 4 30 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 22 Right Handlebar Switch 4 place under fuel cell right side 95 Clutc...

Page 248: ...r open on GY O wire between ignition relay and fuse Check for 12 volts on ignition relay Terminal 30 GY O Voltage present Replace ignition relay See 7 9 RELAY BLOCK Check for 12 volts on ignition relay Terminal 86 W BK Voltage present Repair open on W BK wire between connector 22 and ignition relay YES Remove seat and check ignition fuse Is fuse OK YES Replace ECM See 4 29 ELECTRONIC CONTROL MODUL...

Page 249: ...e up any spilt fuel immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 3 See Figure 4 32 Attach FUEL PRESSURE GAUGE Part No HD 41182 to Schraeder valve on fuel supply fitting a Verify that fuel valve 2 and air bleed petcock 4 on the gauge are closed b See Figure 4 33 Remove prot...

Page 250: ...autions could result in death or serious injury 7 See Figure 4 33 Turn engine off Detach pressure gauge from Schraeder valve a Open the air bleed petcock to relieve fuel system pressure and purge the pressure gauge of gasoline b Remove pressure gauge from valve c Install protective cap on valve DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test...

Page 251: ...tion Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY LowFuel Lamp GY BN Y BN Y Electronic Control Module ECM Connector 10 Connector 11 BK Y R O O Instruments 39 Fuel Pump GY 86B 86A Table 4 11 Wire Harness Connectors in Figure 4 35 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 39 Instruments 10 place Multilock under fuel cell 86 Fuel Pump 4 p...

Page 252: ...mp side of con nector 89 during first two seconds after key ON Is volt age greater than 1 VDC Check for restricted pump inlet screen Is screen restricted NO Move negative probe to GY wire on Terminal 87 of ignition relay Measure voltage during first two seconds after key ON Is voltage greater than 1 VDC YES Locate and repair poor connection between ignition relay and fuel pump NO Move negative pro...

Page 253: ...nal Probe BN Y wire at 86A during the first two seconds after key ON Does test lamp light YES NO Connect Breakout Box HD 42682 to ECM Check continuity between 86A Ter minal C BN Y wire and ECM connector 10 black Termi nal 3 Is continuity present Inspect fuel pump wiring Is wiring OK YES NO Repair fuel pump wiring NO Replace fuel pump assembly See 4 39 FUEL PUMP YES Locate and repair open on BN Y w...

Page 254: ...NTROL 4 15 ADJUSTMENTS See Figure 4 36 Use the adjuster attached to the throttle body to make idle speed adjustments Normal idle speed 850 1050 RPM Figure 4 36 Idle Adjustment Screw Typical 1 6811 1 Idle Adjustment Screw Cable not shown 2 Stop Plate 2 ...

Page 255: ...lug cable from spark plug and igni tion coil For best results use a needle nose pliers for removal installation on coil Gently grasp cable as close to terminals as possible b Using an ohmmeter touch probes to terminals on each end plug wire c Compare resistance values to Table 4 12 Replace cables not meeting specifications Reinstall and repeat procedure on other spark plug cable 3 If carbon tracki...

Page 256: ...n 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY Y BE Y BE Table 4 13 Wire Harness Connectors in Figure 4 38 NO 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 P...

Page 257: ...lty plug wire connections and wire boots for carbon tracking Are wires OK YES Check for Faulty worn or cracked spark plug s Plug fouling due to engine mechanical fault Faulty or poor connection at plug NO Replace faulty wires YES Coils should be free of carbon tracking Are they NO Replace ignition coil YES Switch coil with unit known to be good Perform spark test Did spark jump gap during engine c...

Page 258: ...ce between battery positive and coil connector 83 Terminal B W BK Wiggle harness Is resistance continuously less than 1 0 ohm YES Replace cam sensor with a unit known to be good Does problem still exist NO Find source of intermittent and repair YES Install original cam sensor Replace ECM See 4 29 ELECTRONIC CONTROL MODULE NO OK 5 6 7540 7541 7542 ...

Page 259: ...aged terminals poor terminal to wire connection and damaged harness Perform 4 8 WIGGLE TEST to locate intermittents If connections and harness check out OK monitor TP sen sor voltage using a Scanalyzer or DVOM while moving related connectors and wiring harness If the failure is induced the TP sensor display will change TP sensor scaling Observe the TP sensor voltage dis play while opening the thro...

Page 260: ...ECM Connector 10 Connector 11 Cam Position Sensor R W 5 volt reference V Y TP sensor signal BK W sensor ground R W V Y GN W BK W A B C 14 BK W R W GN W Table 4 14 Wire Harness Connectors in Figure 4 41 NO 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 ...

Page 261: ... flow chart Follow steps while wiggling harness and monitoring DVOM NO Replace TP sensor 4 35 THROTTLE POSI TION SENSOR Clear codes if Scanalyzer is available and road test did check engine lamp come on and set CODE 11 NO System now OK YES Install original TP sensor and replace ECM 4 29 ELECTRONIC CONTROL MODULE Road test again to verify YES Connect Breakout Box if not already connected Disconnect...

Page 262: ... Find short to ground on V Y wire NO Check continuity from Pin 2 of connector 11 to Terminal B on connector 88 Continuity present YES Locate and repair open in V Y wire NO Replace TP sensor See 4 35 THROTTLE POSITION SENSOR YES 7590 7580 7605 Locate and repair open in R W wire NO Check continuity between connector 88 Terminal B V Y wire and Pin 2 of connector 11 Continuity present YES 7615 Locate ...

Page 263: ...sor failure Check for the following conditions Poor connection Inspect the ECM harness connector 11 fuel injector connectors 84 85 and O2 sensor con nector wiring for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Dirty stuck open injectors The motorcycle may run lean dirty clogged injectors or rich stuc...

Page 264: ... b0529x4x Oxygen Sensor 137 Electronic Control Module ECM Connector 10 Connector 11 V GY V GY 1 137B 137A Table 4 15 Wire Harness Connectors in Figure 4 44 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under tail section 137 Oxygen Sensor 1 place above starter ...

Page 265: ...VOM to Pin 4 and Pin 8 of connector 11 gray or use Scanalyzer Turn ignition ON and start engine Engine must be on and running for Scanalyzer to read O2 sensor values Observe O2 voltage Is it approximately 0 5 volts Install Breakout Box HD 42682 leaving harness side connector 11 disconnected from the Breakout Box Is the O2 voltage approximately 0 5 volts YES NO Inspect V GY wire for shorts to volta...

Page 266: ...urn ignition OFF and reconnect O2 sensor Turn ignition ON and start engine Allow engine to reach operating temperature Does voltage quickly flunctuate between 0 4 0 6 volts NO YES Check for restricted fuel filter or fuel line Restriction present NO Check for air leaks at induction module Air leak present YES Replace fuel line or filter NO Fuel injectors may be dirty See Fuel Injectors under 4 40 T...

Page 267: ...d set CODE 13 NO System now OK YES Install original O2 sensor and replace ECM 4 29 ELECTRONIC CON TROL MODULE Road test again to verify YES See Code 13 Test Part 2 of 3 for diagnostic material NO Continued from Code 13 Test Part 2 of 3 Turn ignition OFF and reconnect O2 sensor Turn ignition ON and start engine Allow engine to reach operating temperature Does voltage quickly flunctuate between 0 4 ...

Page 268: ... insulation Check the following conditions Poor connection Inspect ECM harness connector 11 for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Shifted sensor The temperature to resistance values table may be used to test the ET sensor at various tem perature levels in order to evaluate the possibility of...

Page 269: ...ctronic Control Module ECM Connector 10 Connector 11 PK Y 1 90A 90B Engine Temperature Sensor Location b0801x4x REAR CYLINDER Table 4 17 Wire Harness Connectors in Figure 4 45 NO 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 ...

Page 270: ...EMPERATURE SENSOR YES Using a DVOM measure the resistance between Pin 9 of 11 and Pin 2 of 10 and Pin 11 of 10 on Breakout Box Is it greater than 1 0 megaohm NO Examine PK Y wire in harness for open circuit and repair YES NO Examine harness for short to ground and repair Clear codes and confirm proper operation with no check engine lamp At some point in the flow chart you may be instructed to jump...

Page 271: ...come on and set only CODE 14 With ET sensor disconnected dis connect ECM connector 11 Mea sure resistance between ECM Pin 9 of 11 and Pin 2 of 10 Is resistance less than 1 ohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 9 of 11 and Pin 2 of 10 on Breakout Box Is the voltage 0 volts Install original ET sen sor replace ECM 4 29 ELECTRONIC CON TROL MOD...

Page 272: ...ged harness Perform 4 8 WIGGLE TEST to locate intermittents If connections and harness check out OK use the Scana lyzer to check intake air temperature reading while mov ing related connectors and wiring harness If the failure is induced the IAT sensor display will change Shifted sensor The temperature to resistance values table may be used to test the ET sensor at various tem perature levels in o...

Page 273: ...10 Connector 11 Lt GN Y Intake Air Temperature Sensor 89 Lt GN Y 5 volt reference and sensor signal BK W sensor ground 1 2 BK W Lt GN Y Installed IAT Sensor 6769 P89B P89A Table 4 19 Wire Harness Connectors in Figure 4 46 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under tail section 89 IAT Sensor 2 place Deutsch inside air box ...

Page 274: ...TEMPERA TURE SENSOR clear codes if Scanalyzer is available and road test Did check engine lamp come on and set only CODE 15 With IAT sensor disconnected dis connect ECM connector 11 Mea sure resistance between ECM Pin 10 of 11 and Pins 2 and 11 of 10 Is resistance less than 1 megaohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 10 of 11 and Pin 2 of ...

Page 275: ...he resistance between ECM Pins 10 and 7 of connector 11 on Breakout Box Is it greater than 1 0 megaohm NO Examine BK W wire in harness for open circuit and repair YES Using a DVOM measure the resistance between ECM Pin 10 of connector 11 on Breakout Box and ground Is it greater than 1 0 megaohm NO Examine Lt GN Y wire and BK W wire in harness for short between these two circuits and repair YES NO ...

Page 276: ... numbers below correlate with the circled num bers on the Code 16 flow charts 1 The ECM is monitoring voltage at ECM connector 10 black Terminal 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX 2 This checks for voltage drops in the ECM power circuit If a significant voltage drop is not present condition may be caused by excessive starter current draw 3 See 5 5 DIAGNOSTICS TROUB...

Page 277: ...K R GY R BK R BK R BK R BK GY O Ignition 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY GY Table 4 20 Wire Harness Connectors in Figure 4 49 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section ...

Page 278: ... Pin 1 of 10 on Breakout Box with key ON Is voltage drop greater than 0 5 volt System OK YES NO Check for excessive starter current draw See Section 5 Measure voltage drop between Battery Positive Terminal and Terminal 87 on ECM safety interlock relay with key ON Is voltage drop greater than 0 5 volt NO Replace ignition relay 7 9 RELAY BLOCK 1 2 Clear codes and confirm proper operation with no che...

Page 279: ...Terminal and silver post of 30 amp circuit breaker with key ON Is voltage drop greater than 0 5 volt YES NO Repair R wire or terminals Measure voltage drop between Battery Positive Terminal and copper post of 30 amp circuit breaker with key ON Is voltage drop greater than 0 5 volt YES NO Replace circuit breaker Replace BK wire between circuit breaker and battery 7781 YES Measure voltage drop betwe...

Page 280: ...e in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gas before removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 1 Purge fuel line and remove fuel tank See 4 36 FUEL TANK ...

Page 281: ...Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 GY b0543x4x 1 2 1 2 Rear Fuel Injector 85 Front Fuel Injector 84 W Y W Y GN GY GY GN GY GY GY Table 4 21 Wire Harness Connectors in Figure 4 52 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 84 Front Injector 2 place under fuel cell 85...

Page 282: ...ctor connector 85 Is resistance less than 0 5 ohm YES Check for loose or corroded terminals in harness Repair as necessary Replace injector See 4 40 THROTTLE BODY AND INTAKE MANI YES NO NO Go to Code 23 32 Test Part 2 of 2 YES NO Repair open or poor connection Using Breakout Box check with test lamp between ECM 10 Pin 5 CODE 23 or ECM 10 Pin 8 CODE 32 and ECM 10 Pin 1 Does light flash when cranked...

Page 283: ...nnector Is resistance less than 0 5 ohm With DVOM still attached perform 4 8 WIGGLE TEST to locate intermittents Repair as necessary Find and repair connection or open wire YES NO 1 With the engine off Scanalyzer Active Diagnostic Test Mode can be used to energize either the front or rear injector once each second for a total of five seconds 2 With the engine off Scanalyzer Active Diagnostic Test ...

Page 284: ... from the cam position sensors at which time it is reactivated DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 24 25 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 purple pin probes and patch cord 2 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX Scanalyzer Notes The Scanalyzer icon appears at those points in...

Page 285: ... 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY Front Spark Plug Rear Spark Plug Y BE Y BE Table 4 22 Wire Harness Connectors in Figure 4 55 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 83 Ignition Coil Connector 3 place ...

Page 286: ...e resistance between ECM and coil terminals as follows Resistance should be less than 0 5 ohms Is it Trouble Code Coil Terminal ECM Terminal 24 Front C BE O 6 25 Rear A Y BE 7 NO Repair open wire or connection YES Perform 4 8 WIGGLE TEST Intermittents found NO YES Repair as necessary 2 2 1 1 With the engine off Scanalyzer Active Diagnostic Test Mode can be used to energize either the front or rear...

Page 287: ...gnostic Notes The reference numbers below correlate with the circled num bers on the Code 33 flow chart 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 red pin probe and patch cord 3 Use HARNESS CONNECTOR TEST KIT gray socket probe and patch cord Scanalyzer Notes The Scanalyzer icon appears at those points in the flow chart wher...

Page 288: ...ion Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY Low fuel lamp GY BN Y Electronic Control Module ECM Connector 10 Connector 11 O O Instruments 39 GY BN Y BK Y R Fuel Pump 86B 86A Table 4 23 Wire Harness Connectors in Figure 4 58 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 39 Instruments 10 place Multilock under fuel cell 86 Fuel Pump 4 p...

Page 289: ... FUEL PUMP Clear codes if Scan alyzer is available and road test Did check engine lamp come on and set only CODE 33 YES NO Install original fuel pump 4 39 FUEL PUMP and replace ECM 4 29 ELECTRONIC CONTROL MODULE System OK Fuel pump on continuously YES Locate and repair short to ground on BN Y wire NO Check continuity of BN Y wire between 10 Pin 3 and Pin C of 86 Continuity present YES Repair open ...

Page 290: ...upply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gas before removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 2 Purge fuel line and remove fuel tank to access instru ment connector 39...

Page 291: ...y 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker Instruments 39 Tachometer PK PK To Starter Interlock Circuit O Electronic Control Module ECM Connector 10 Connector 11 Table 4 24 Wire Harness Connectors in Figure 4 61 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under tail section 39 Main Harness to Instruments 10 place Multilock un...

Page 292: ...nuity at Breakout Box between Pin 12 and Pin 11 in connector 10 Continuity present Locate and repair short on PK wire to ground YES Plug in 10 Connect voltmeter across Pin 12 and Pin 11 at Breakout Box 10 Start engine and let motor idle Is voltage approximately 4 0 6 0 volts NO Clear codes and confirm proper operation with no check engine lamp Reconnect 39 Locate intermittents using 4 8 WIGGLE TES...

Page 293: ...e occurs the engine may stop running The engine may still be restarted and ridden to the dealership for repair DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 44 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gray pin probes and patch cord 2 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX Figure 4 62 Bank Ang...

Page 294: ... GN GY BK GY GY Lt GN GY BK GY GY R R R GY R BK R GY R BK R BK R BK R BK GY O Ignition 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY GY 86 Table 4 25 Wire Harness Connectors in Figure 4 64 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under...

Page 295: ...GN wire 4 0 6 0 volts Measure voltage between Socket C GY and Socket B BK Is voltage 11 13 volts 11 13 volts 0 volts Go to Code 44 Test Part 2 of 2 YES Is bank angle sensor correctly installed NO Repair open in GY wire between 134 and harness YES Are ferrous metals located within 0 25 in 6 4 mm of sides face or top of bank angle sensor NO Install bank angle sensor properly See 4 33 BANK ANGLE SENS...

Page 296: ...n 10 Is continuity present NO Repair open in Lt GN GY wire YES Check continuity to ground for Socket B BK and connector 11 Pin 8 Is continuity present NO Repair open in ground wire YES Check continuity to ground for Socket A Lt GN GY and connector 134 Is continuity present NO Replace ECM See 4 29 ELECTRONIC CONTROL MODULE Check for codes YES Repair short to ground on Lt GN GY wire Clear codes and ...

Page 297: ...es indicate a failure which requires replacement of the ECM See 4 29 ELECTRONIC CONTROL MODULE Code 52 RAM failure Code 53 ROM failure 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 ...

Page 298: ...ay continue to run not run normally or stop running altogether DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 56 flow charts 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 black pin probes and patch cord 3 See 4 30 CAM POSITION SENSOR AND ROTOR Figure 4 65 Cam Position S...

Page 299: ...h under tail section 14 Cam Position Sensor 3 place Deutsch near starter 88 TP Sensor 3 place Packard behind air cleaner backplate C B A b0526x4x Throttle Position Sensor 88 R W V Y BK W b0527x4x R W BK W GN W Cam Position Sensor 14 R W 5 volt reference GN W sensor signal BK W sensor ground Electronic Control Module ECM Connector 10 Connector 11 A B C R W V Y GN W BK W BK W GN W R W ...

Page 300: ...ES NO Measure continuity between Pin A on 14 and Pin 1 on 11 Continuity present Disconnect harness side connector 11B GY from Breakout Box Measure voltage between Pin 1 and Pin 7 of connector 11 Voltage present NO Repair open in R W wire between connectors 11 and 14 NO Repair open in BK W wire between connectors 11 and 14 YES YES 12 volts Locate and repair R W wire short to voltage Locate and repa...

Page 301: ...r R W Perform 4 8 WIGGLE TEST and repair intermittent YES NO Repair Remove timing cover and cam position sensor Observe rotor cup while cranking engine Does rotor turn YES Check rotor for damage Is rotor loose or damaged NO Is rotor attached properly YES Remove gearcase cover and inspect for damage NO Repair YES Replace rotor and retest NO Replace cam position sensor and clear code Retest Prob lem...

Page 302: ... and 11 3 If installing a new ECM calibrate throttle position sensor using SCANALYZER Part No HD 41325 See 4 35 THROTTLE POSITION SENSOR 11WARNING 1WARNING 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 4 Instal...

Page 303: ...e 3 Fuel pump output 4 Check engine lamp 5 Injector front output 6 Front coil primary 7 Rear coil primary 8 Injector rear output 9 No function 10 Bank angle sensor input 11 System ground B coil 12 Tachometer out Table 4 28 Pin Table for ECM Connector 11 Gray PIN FUNCTION 1 5 volt sensor power 2 Throttle position sensor 3 Camshaft position sensor 4 Oxygen sensor 5 No function 6 No function 7 Sensor...

Page 304: ... timer cover pop rivets using a 3 8 in 9 525 mm drill bit b Tap remaining rivet shafts inboard through holes in timer cover and inner cover c Remove timer cover Remove inner cover screws and inner cover d Carefully remove any remaining pieces of rivets from gearcase cover timer bore 9 See Figure 4 70 To obtain approximate ignition timing during installation scribe alignment marks across cam positi...

Page 305: ...connector 14 R W GN W and BK W wires of plug end from cam position sensor must match same color wires in receptacle end of con nector from ignition module wiring harness Install pin terminals See Appendix B 6 See Figure 4 69 Attach connector 14 7 Check ignition timing See 1 19 IGNITION TIMING 8 Tighten timer plate studs to 15 30 in lbs 2 3 Nm 9 Install inner cover using screws Tighten to 12 20 in ...

Page 306: ... 1 See Figure 4 73 Unplug 1 place connector 137 under battery tray 2 Remove oxygen sensor from exhaust header using a 22 mm or 7 8 in crow s foot or flare nut socket INSTALLATION 1 Apply LOCTITE ANTI SEIZE LUBRICANT to threads of sensor Make sure anti seize is marked as safe for use with O2 sensors 2 See Figure 4 73 Thread sensor into exhaust header Tighten to 42 45 ft lbs 57 61 Nm 3 Connect 1 pla...

Page 307: ...n engine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 1 See Figure 4 75 Screw sensor into rear cylinder head with special ET sensor socket Make sure wire is in cut out portion slot of socket to prevent damage Tighten ET sensor to 10 14 ft lbs 14 19 Nm 2 Install rubber boot to ET Sensor wire push wire through hole in boot with smaller OD side towards sensor 3 Pu...

Page 308: ... angle sensor to frame using screw washer and nut 3 Make sure location post on sensor engages hole in mounting tab 3 Tighten screw to 25 27 in lbs 2 8 3 1 Nm 11WARNING 1WARNING 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 se...

Page 309: ...CLEANER 3 Disconnect connector 89 from intake air temperature sensor 4 Remove IAT sensor from top of snorkel INSPECTION Inspect sensor grommet for damage and replace as required INSTALLATION 1 Install IAT sensor and grommet into snorkel 2 Connect IAT sensor connector 89 to sensor 3 Place a small piece of double sided tape at the upper center of the air filter foam gasket that fits against the back...

Page 310: ...y switch to IGNITION Turn the handlebar mounted Engine Stop Switch to the RUN posi tion but do not start the engine 6 Calibrate TP sensor using Scanalyzer Part No HD 41325 a From Diagnostic Menu press 7 to display Calibra tion Menu b Press 1 to activate TPS Zero Function c Press Enter to verify throttle plate is fully closed Scanalyzer will then calibrate sensor 7 Set idle speed a Press the mode k...

Page 311: ...emaining fuel from fuel line 2 See Figure 4 82 Remove seat Remove bolt mounting plates and retention plates from rear tank mount See 2 35 SEAT 3 Prop fuel tank against frame to gain access to fuel sup ply fitting Wrap a shop towel around the fuel supply fit ting 11WARNING 1WARNING A small amount of gasoline will drain from the fuel sup ply fitting and fuel line when removed Thoroughly wipe up any ...

Page 312: ...top of fuel tank b See Figure 4 85 Tighten screws to 22 25 in lbs 2 5 2 8 Nm in the order shown 8 Install vent valve See 4 37 FUEL TANK VENT VALVE 9 Perform Fuel Tank Pressure Test CLEANING AND INSPECTION 11WARNING 1WARNING An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank Use extreme caution when servicing fuel tanks Gasoline is extremely fl...

Page 313: ...th a new clamp 8 Attach 4 place fuel pump connector 86 11WARNING 1WARNING 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 9 Install seat See 2 35 SEAT NOTE Use a good quality unleaded gasoline 91 pump octane or h...

Page 314: ...itable clean container b See instructions for external fuel pump for correct use 4 See Figure 4 84 Cut cable tie holding vent hose to fitting and remove vent hose from fuel tank 5 While holding vent valve with angled needle nose pliers remove fitting from vent valve 6 Pull the vent valve from the gasket and remove from fuel tank INSTALLATION 1 Wipe inside and outside vent valve mounting hole to ma...

Page 315: ...12 00 position when tighten ing within specified torque range loosen fitting rotate vent valve and try again Repeat as required to get proper align ment of nozzle within specified torque range 8 See Figure 4 84 Attach vent hose to nozzle on fitting with new cable tie 9 Fill fuel tank with proper fuel 91 Octane and install gas cap 10 Connect negative battery cable Tighten to 40 in lbs 4 5 Nm 11 Pre...

Page 316: ...tremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 4 See Figure 4 88 Remove hose clamps from both sides to detach filter 5 Position new filter in bracket with arrow pointing in direc tion of fuel flow Install two cable ties around filter and bracket NOTE If bracket was removed for any reason tighten bolt to 30 33 ft lbs 41 45 Nm 11WARNING 1...

Page 317: ...ure 4 89 Remove fuel fitting nut 1 5 Remove electrical fitting nut 5 washer sealing washer and rubber seal 6 6 Push electrical and fuel fitting studs back into tank 7 Reach inside fuel filler cap hole and remove pump assembly REPAIR Fuel Pump Replacement 1 Remove fuel pump assembly from tank 2 See Figure 4 90 Remove retaining clamp 5 from pump body 4 using a pair of cutters 3 Pull pump outlet fitt...

Page 318: ... c Feed wire into tank through fuel filler cap hole and out through electrical fitting hole smaller hole in bottom of tank Gently pull on wire to seat pump 3 Install pump assembly inside tank through fuel filler cap hole Position pump assembly with filter facing motorcy cle license plate When properly aligned press both studs through the holes in the bottom of tank 4 Install new O ring on brass ad...

Page 319: ...pressure gas before removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 1 Purge fuel line and remove fuel tank See 4 36 FUEL TANK 2 Remove air cleaner cover and backplate See 4 41 AIR CLEANER 3 See Figure 4 94 On California models pull EVAP hose from fitting 3 Figure 4 94 Throttle Body and Intake Manifold 1 2...

Page 320: ...right side of the bike frame 8 Remove intake flanges 14 from intake manifold Remove and discard seals 15 REPAIR Throttle Position Sensor See 4 35 THROTTLE POSITION SENSOR for removal installation and calibration procedures Fuel Injectors REMOVAL 1 Remove throttle body and intake manifold 2 See Figure 4 96 Separate fuel rail assembly 3 from intake manifold a Remove both injector clips 4 b Remove sc...

Page 321: ...o manifold with the counterbore facing out Each intake flange is labeled and the pieces are not inter changeable 2 Place a new seal in each intake flange with the beveled side against the counterbore 3 See Figure 4 99 Attach both throttle cables Add free play to cables if necessary a With the manifold assembly close to the right side of the bike but not fully installed place idle control cable end...

Page 322: ...g c Make sure throttle body is centered between cylin ders and tighten all intake flange screws to 6 10 ft lbs 8 14 Nm 6 Attach wiring a Injector cables are tagged F ront and R ear for ease of assembly Push connector halves together until latches click Grooves in female connector must align with the tabs in male housing b Connect throttle position sensor by pushing the con nector halves together S...

Page 323: ... hoses a Detach breather tee 4 from rear breather hose 1 b Detach front breather hose 3 from front breather bolt 2 8 Before the snorkel is removed detach IAT sensor a See Figure 4 105 Press the catch on the intake air temperature IAT sensor b While holding catch remove sensor from the snor kel by pulling upward 9 See Figure 4 106 Remove two screws 1 and snorkel plate 2 Remove snorkel 3 10 Before t...

Page 324: ...stall nuts 2 Tighten to 3 5 ft lbs 4 7 Nm 5 Attach IAT sensor to snorkel See Figure 4 105 6 See Figure 4 106 Install snorkel a Apply LOCTITE THREADLOCKER 243 blue to screws 1 b Align snorkel 3 on spacer 4 and spacer screw c Attach snorkel to backplate assembly using snorkel plate 2 and two screws 1 Tighten to 6 8 ft lbs 8 11 Nm 7 See Figure 4 103 Install front breather hose 3 on front breather bol...

Page 325: ...e canister vent hose These vapors pass through the throt tle body and are burned as part of normal combustion in the engine The large diameter canister to air cleaner backplate hose canister fresh air inlet hose supplies the canister with fresh air from the air cleaner TROUBLESHOOTING 11WARNING 1WARNING Verify that the evaporative emissions system hoses do not contact hot exhaust or engine parts T...

Page 326: ...h mounting plate 2 from clamps 1 5 Remove countersunk screws and locknuts 5 to sepa rate bracket 4 from mounting plate 2 INSTALLATION Vent Valve 11WARNING 1WARNING Verify that the fuel tank vent hose does not contact hot exhaust or engine parts The hose contains flammable vapors that can be ignited if damaged which could result in death or serious injury 1 Install vent valve See 4 37 FUEL TANK VEN...

Page 327: ...ect to and that hose clamps are properly tightened and positioned on straight section of fitting and not on the fitting barb Failure to comply may result in fuel leakage which could result in death or seri ous injury NOTE The barb is the larger outside diameter portion bump on the fuel fitting 2 Connect fuel tank vent hose 1 and canister vent hose 2 to the carbon canister Canister vent hose attach...

Page 328: ...Electric Starter System 5 2 5 3 Starting System Diagnosis 5 6 5 4 Starter Activation Circuits 5 8 5 5 Diagnostics Troubleshooting 5 9 5 6 Starter System Testing 5 11 5 7 Starter 5 12 5 8 Starter Solenoid 5 19 Table Of Contents ELECTRIC STARTER 5 ...

Page 329: ......

Page 330: ...Stall Current 400 amp max 2 4 V Stall Torque 8 1 ft lbs 11 Nm min 2 4 V SERVICE WEAR LIMITS IN MM Brush Length minimum 0 433 11 0 Commutator Diameter minimum 1 141 28 981 ITEM TORQUE NOTES Battery Terminal Bolts 60 96 in lbs 7 11 Nm metric Starter Battery Positive Cable Nut 60 85 in lbs 7 10 Nm metric Starter Mounting Bolts 13 20 ft lbs 18 27 Nm 5 ...

Page 331: ...nt flows into the pull in winding 10 and the hold in winding 11 to ground The magnetic forces of the pull in and hold in windings in the solenoid push the plunger 7 causing it to shift to the left This action engages the pinion gear 1 with the clutch ring gear 13 At the same time the main solenoid contacts 8 are closed so battery current flows directly through the field windings 3 to the armature ...

Page 332: ...rting circuit see wiring diagram Starting circuit see wiring diagram 1 Pinion Gear 2 Idler Gear 3 Field Winding 4 Armature 5 Brush 6 Ball Bearing 7 Solenoid Plunger 8 Main Solenoid Contacts 9 Battery 10 Pull in Winding 11 Hold in Winding 12 Overrunning Clutch 13 Clutch Ring Gear Starter at moment starter switch is closed Starter during cranking ...

Page 333: ...n nection Replace Solenoid Poor contact condition caused by burnt contact Contact plate removed Pull in winding open or short cir cuited Hold in winding open Polish contact surface or replace solenoid assembly Repair Replace solenoid assembly Replace solenoid assembly Starting motor Poor contact condition of brushes Commutator burnt Commutator high mica Field winding grounded Armature winding grou...

Page 334: ...ning clutch malfunction roll ers or compression spring Pinion teeth worn out Pinion does not run in overrunning direction Poor sliding condition of spline teeth Reduction gears damaged Replace overrunning clutch Replace overrunning clutch Replace overrunning clutch Remove foreign materials dirt or replace overrunning clutch Replace overrunning clutch and idler gear Ring gear Excessively worn teeth...

Page 335: ...tery Voltage Present With Starter Button Pressed Check for Ground at Relay Terminal 85 Ground Present Inspect Starter Interlock Circuit or Correct Relay Ground Check for Battery Voltage to Starter Button W BK Wire Battery Voltage Present Replace Right Handlebar Switchgear NO Repair Wiring to Starter Button YES YES Repair Wiring From Starter Button to Relay NO YES YES NO NO 1 Perform Voltage Drop T...

Page 336: ... Button NOT Pressed Replace Right Handlebar Switchgear Replace Starter Relay Replace Solenoid YES NO NO YES NO NO YES Perform Voltage Drop Test Between Battery Neg and Starter Studs or Bolts Is Voltage Greater than 1 Volt Clean Ground Connections NO YES Perform Voltage Drop Tests from Battery Pos to Starter Battery Terminal Crank Engine Is Voltage Greater than 1 Volt YES NO Repair Connection Betwe...

Page 337: ... 150A 20A 20A 0 1A 150A 0 1A 150A 20A 20A 0 1A 150A 0 1A 150A 20A 20A 0 1A 150A 0 1A VDC ITEM A IDEAL CLOSED CIRCUIT GROUND CIRCUIT OPEN CIRCUIT b0157x5x OV VDC VDC 12V OV ITEM B ITEM C ITEM D 1 1 Start Switch 2 Relay 3 Solenoid 4 Starter 5 Battery 6 Main Circuit Breaker 7 Ignition Switch 8 Ignition Circuit Breaker 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 ...

Page 338: ...ing all the voltage dropped and the entire difference in potential displayed on the meter 6 Typically a good circuit will drop less than 1 volt 7 If the voltage drop is greater back track through the con nections until the source of the potential difference is found The benefit of doing it this way is speed a Readings aren t as sensitive to real battery voltage b Readings show the actual voltage d...

Page 339: ... GN R BK TN GN DIODE 1 DIODE 2 62 TN FUSE BLOCK IGNITION 15A 15A 15A ACCESSORY LIGHTS 15A INSTRUMENTS 61 MEMORY SPARE 20A 15A 15A SPARE 20A 15A SPARE SPARE BR K R BR R K R B R K R GY KEY SWITCH OFF P IGN A B C D 33 S7 BATTERY BK GN BK R MASTER CIRCUIT BK MAIN CHASSIS GROUND TN SWITCH NEUTRAL COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELL...

Page 340: ... proceed to STARTER CURRENT DRAW TEST Starter Current Draw Test NOTE Engine temperature should be stable and at room tem perature Battery should be fully charged See Figure 5 8 Check starter current draw with an induction ammeter before disconnecting battery Proceed as follows 1 Verify that transmission is in neutral Disconnect spark plug wires from spark plug terminals 2 Clamp induction ammeter o...

Page 341: ... 1 Place starter in vise using a clean shop towel to prevent scratches or other damage 2 See Figure 5 11 Attach one heavy jumper cable 6 gauge minimum a To the starter mounting flange 1 b To the negative terminal of a fully charged bat tery 3 Connect a second heavy jumper cable 6 gauge mini mum a To the positive terminal of the battery 2 b To an inductive ammeter 3 Continue on to the bat tery term...

Page 342: ...See Figure 5 13 With test leads still connected in the manner specified in the previous SOLENOID PULL IN TEST disconnect solenoid motor terminal battery negative test lead B at negative battery post only reconnect loose end of this test lead to positive bat tery post instead 2 Observe starter pinion a If starter pinion remains in pull in position solenoid is working properly b If starter pinion do...

Page 343: ...n commutator Otherwise abrasive grit may remain on commutator segments this could lead to excessive brush wear Use only the recommended crocus cloth 8 Check depth of mica on commutator If undercut is less than 0 008 in 0 203 mm use an undercutting machine to undercut the mica to 1 32 in 0 794 mm deep The slots should then be cleaned to remove any dirt or cop per dust See Figure 5 18 If an undercut...

Page 344: ...f there is continuity then the armature is grounded Replace grounded armatures Figure 5 18 Undercutting Mica Separators Mica must not be left with a thin edge next to segments Right Way Mica Undercutting mica with piece of hacksaw blade Wrong Way Starting groove in mica with 3 cornered file Mica must be cut away clean between segments b0136x5x Mica Segments Segments Figure 5 19 Shorted Armature Te...

Page 345: ...ust be replaced 13 See Figure 5 23 Check for OPEN FIELD COILS with an ohmmeter or continuity tester a Touch one probe to the field wire 1 b Touch the other probe to each of the brushes attached to the field coil s 2 c There should be continuity 0 ohms If there is no continuity at either brush then the field coil s are open and the field frame must be replaced 14 See Figure 5 24 Test BRUSH HOLDER I...

Page 346: ...ing 10 to solenoid housing 11 use new O ring 16 Be sure to install return spring 17 and ball 18 Figure 5 25 Starter Drive Assembly 4 O Ring 5 Drive Housing 6 Screws 1 Drive 2 Idler Gear 3 Idler Gear Bearing 1 2 3 4 5 6017 6 Figure 5 26 Starter Assembly 1 Thru Bolt 2 2 End Cover Screw and O Ring 2 3 End Cover 4 Brush Holder 5 Brush Spring 4 6 Armature 7 Field Frame 8 Armature Bearing 2 9 Drive Hous...

Page 347: ...re 4 b Attach circuit breaker wire ring terminal 3 c Attach positive battery cable ring terminal 2 d Install nut with washer 1 metric Tighten to 60 85 in lbs 7 10 Nm e Replace protective boot if equipped 3 See Figure 5 9 Install both starter mounting bolts and washers Tighten to 13 20 ft lbs 18 27 Nm 4 Install primary cover See PRIMARY COVER under 6 2 PRIMARY CHAIN 5 Fill transmission to proper le...

Page 348: ...nd a hollow cylinder con taining a movable plunger DISASSEMBLY 1 See Figure 5 27 Remove screws 1 and clip 2 2 Remove cover 3 and gasket 4 Discard gasket 3 Remove plunger 5 from solenoid housing 6 ASSEMBLY 1 See Figure 5 27 Replace wire connection hardware as necessary 2 Install plunger 5 in solenoid housing 6 3 Install new gasket 4 onto cover 3 4 Position cover with gasket onto solenoid housing In...

Page 349: ...5 20 2002 Buell S3T Electric Starter HOME NOTES ...

Page 350: ... Clutch 6 10 6 6 Transmission 6 17 6 7 Transmission Case 6 19 6 8 Shifter Forks and Drum 6 21 6 9 Mainshaft and Countershaft 6 23 6 10 Main Drive Gear 6 29 6 11 Access Door Bearings 6 31 6 12 Right Transmission Case Bearings 6 32 6 13 Transmission Installation and Shifter Pawl Adjustment 6 33 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 351: ......

Page 352: ...Clutch Fluid Capacity 1 0 quart 0 95 liter Fluid Part No Quart 98854 96 Fluid Part No Gallon 98855 96 TRANSMISSION GEAR RATIOS FINAL OVERALL First Low Gear 2 69 9 047 Second Gear 1 85 6 687 Third Gear 1 43 4 823 Fourth Gear 1 18 3 973 Fifth High Gear 1 00 3 366 PRIMARY DRIVE ENGINE TO TRANSMISSION Engine Sprocket 35 teeth Clutch Sprocket 56 teeth Ratio 1 60 1 FINAL DRIVE TRANSMISSION TO REAR WHEEL...

Page 353: ...er Locknut 20 25 ft lbs 27 34 Nm on exterior of chaincase Primary Chain Inspection Cover Screws 40 60 in lbs 5 7 Nm Primary Cover Screws 100 120 in lbs 11 14 Nm 3 lengths Large primary cover screws 16 28 ft lbs 22 38 Nm Rear Shock Mounting Bolt Front 40 45 ft lbs 54 61 Nm metric Rear Shock Mounting Bolt Rear 30 33 ft lbs 41 45 Nm metric Shifter Lever Pinch Screw 59 66 in lbs 7 8 Nm Shifter Lever M...

Page 354: ...hock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or serious injury 1 Disconnect negative cable from battery terminal 2 Raise rear wheel off floor using REAR WHEEL SUP PORT STAND Part No B 41174 3 Remove left fairing lower See 2 38 FAIRING LOWERS 4 Remove muffler See 2 27 EXHAUST SYSTEM 5 See Figure...

Page 355: ...3 Slide shoe 6 off plate 5 shoe must be slid off plate toward closed or blind side of shoe Remove locknut 4 and plate 5 INSTALLATION Primary Chain Adjuster 1 See Figure 6 3 If shoe 6 is badly worn replace it or adjust assembly 2 Install plate 5 over top of chain adjuster screw 3 Place spacer 7 over top of adjuster screw next to plate Secure plate and spacer to adjuster screw by threading on locknu...

Page 356: ...igure 6 5 Apply LOCTITE THREAD LOCKER 243 Blue to shift lever mounting bolt 11 Install shifter lever assembly with mounting bolt washer and plastic bushings and spacer Do not tighten mount ing bolt 12 Install rubber washer and upper shift lever assembly to splined shaft 13 See Figure 6 6 Position upper clamp on splined shaft pointing just below front clutch inspection cover bolt Shift linkage rod ...

Page 357: ...r hoist placed behind the lift Raise motorcycle off lift until rear suspension is unloaded 5 Remove the stone guard and lower belt guard See 2 30 STONE GUARD 6 Remove sprocket cover See 2 29 SPROCKET COVER 7 Remove rear fender See 2 32 REAR FENDER 8 See Figure 6 7 Remove rear wheel a Remove rear axle nut 1 metric lockwasher 2 washer 3 and right side axle carrier 4 b Hold axle adjuster bolt 5 with ...

Page 358: ...age to rubber isola tors See Figure 6 9 2 See Figure 6 8 Install right rear isolator See 2 20 REAR ISOLATORS 3 See Figure 6 9 After tightening isolator bolt verify that seam on isolator is perpendicular to swingarm mount block 4 Install rear fender See 2 32 REAR FENDER 5 Align the new belt and rear wheel See 1 10 DRIVE BELT DEFLECTION 6 Install sprocket cover See 2 29 SPROCKET COVER 7 Install the ...

Page 359: ...rew nut 5 from end of adjusting screw 6 Remove hook of ramp from cable end coupling 16 Remove cable end 10 from slot in coupling 7 Remove and discard retaining ring 13 from ramp assembly to separate inner and outer halves Remove three balls 7 from ramp sockets CLEANING AND INSPECTION 1 Thoroughly clean all parts in cleaning solvent 2 See Figure 6 10 Inspect three balls 7 of release mech anism and ...

Page 360: ...ing inward place hook of ramp around coupling button c Rotate assembly counterclockwise until tang on inner ramp fits in slot of primary cover 6 3 Secure assembly in place a Thread wellnut 2 on adjusting screw 3 until slot of screw is accessible with a screwdriver b Fit nut hex into recess of outer ramp 1 c Turn adjusting screw counterclockwise until resis tance is felt 4 Adjust clutch release mec...

Page 361: ...rom the engine will be transmitted to the rear wheel When the clutch is disengaged clutch lever pulled to left han dlebar grip the pressure plate 6 is pulled outward by clutch cable action against the diaphragm spring 7 thereby compressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch plates 1 2 and 3 together The fiber plates 3 are now fr...

Page 362: ...etaining rings are highly compressed in the ring groove and may fly out with considerable force when pried out of the groove Always wear safety glasses or goggles while removing or installing retaining rings Failure to comply could result in death or serious injury CAUTION See Figure 6 15 Turn compressing tool handle 5 only the amount required to release spring seat 9 and remove snap ring 8 Excess...

Page 363: ...0 Spring Seat 11 Diaphragm Spring 12 Retaining Ring 13 Release Plate 14 Retaining Ring 15 Bearing 16 Adjusting Screw 17 Pressure Plate 18 Fiber Plate 8 19 Steel Plate 6 20 Spring Plate 21 Mainshaft Nut 22 Washer 23 Clutch Hub 24 Retaining Ring 25 Bearing 26 Clutch Shell 27 Retaining Ring b0009c6x 27 26 25 24 23 22 21 20 19 18 17 16 15 14 1 2 3 5 6 7 9 10 11 12 13 8 4 Labeled OUT ...

Page 364: ...kets for damage or excessive wear b Inspect stator and rotor See 7 9 ALTERNATOR c Replace damaged parts as necessary 8 Install adjusting screw assembly into pressure plate a See Figure 6 18 Align two tabs on perimeter of release plate with corresponding recesses in pres sure plate b See Figure 6 17 Secure the adjusting screw assembly with large retaining ring 1 9 Attach tools to compress clutch di...

Page 365: ...h compo nents as follows a Check all clutch plates for wear and discoloration b Inspect each steel drive plate 19 for grooves c Place each steel plate on a flat surface Using a feeler gauge check for flatness in several places Replace any plates that are damaged or are warped more than 0 006 in 0 152 mm 2 Check the diaphragm spring 11 for cracks or bent tabs Install a new spring if either conditio...

Page 366: ...p ring positioned against outboard side of spring seat and fully seated in groove of clutch hub carefully loosen and remove compression tool Primary Drive 1 See Figure 6 22 Assemble clutch hub and shell if nec essary a Press new bearing 3 in clutch shell 4 Secure bearing with a new retaining ring 2 b Press inboard end of clutch hub 1 into shell bear ing 3 Secure with new retaining ring 5 on end of...

Page 367: ...d washer a Apply two or three drops of LOCTITE THREAD LOCKER 262 red onto threads on end of main shaft b Place washer 2 on mainshaft with the word out facing away from clutch hub 3 c Install nut 1 left hand threads Tighten to 70 80 ft lbs 95 109 Nm 4 Remove SPROCKET LOCKING LINK 5 Install adjusting screw assembly into pressure plate a See Figure 6 18 Align two tabs on perimeter of release plate wi...

Page 368: ...oot operated by the gear shift lever which transmits the force through a gear shifter shaft The shifter shaft actuates a pawl and a shifter fork drum 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 LUBRICATION Drain transmission and refill to correct level with fresh clean lubricant a...

Page 369: ... 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 Neutral Power Flow Sliding Member Countershaft Mainshaft Out 1st Gear Countershaft Mainshaft In 2nd Gear Countershaft Mainshaft In 3rd Gear Countershaft Mainshaft Out In 5th Gear Countershaft Mainshaft Out In 4th Gear Countershaft Mainshaft In Out XLH transpower flow ...

Page 370: ... as possible 7 See Figure 6 27 Place transmission in first gear Remove four socket head screws 5 and lockplate 4 CAUTION Transmission sprocket nut has left hand threads To pre vent damage turn nut clockwise to loosen and remove from main drive gear shaft 8 Remove transmission sprocket nut 3 from main drive gear shaft 1 9 Remove secondary drive belt from transmission sprocket 2 Remove transmission ...

Page 371: ...CTION Thoroughly clean transmission compartment with cleaning solvent Blow parts dry with compressed air Inspect parts to determine if any must be replaced Replace all parts that are badly worn or damaged Neutral Indicator Switch See Figure 6 30 The neutral indicator switch is threaded into the transmission portion of the right crankcase half See 7 7 NEUTRAL INDICATOR SWITCH for testing removal an...

Page 372: ...neutral indicator pin prevents removal in the other direction 6 Remove shifter forks 1 2 and 3 CLEANING AND INSPECTION 1 See Figure 6 31 Clean all parts except bearings 19 20 with solvent Figure 6 31 Shifter Mechanism 1 Shifter Fork 3rd and 5th Gear 2 Shifter Fork 1st and 2nd Gear 3 Shifter Fork 4th Gear 4 Cotter Pin 3 5 Shifter Fork Pin 3 6 Neutral Indicator Pin 7 Shifter Fork Drum 8 Shifter Drum...

Page 373: ...erted through the shifter forks as shown in Figure 6 32 This will prevent possible damage to the cotter pins 4 See Figure 6 31 Secure shifter mechanism a Lubricate the three shifter fork pins 5 with SPORT TRANS FLUID b Drop fork pins 5 through the holes in shifter forks c With a small screwdriver press on the pins while manipulating the forks back and forth until the pin seats in the drum groove d...

Page 374: ...location and facing its original direction 3 See Figure 6 35 As each component is removed place it on a clean surface in the exact order of removal 11WARNING 1WARNING Retaining rings are highly compressed in the ring groove and may fly out with considerable force when pried out of the groove Always wear safety glasses or goggles while removing or installing retaining rings Failure to comply could ...

Page 375: ...ocket Belt 15 Seal Oil 16 Spacer Belt Drive 17 Ring Quad 18 Ring Retaining 19 Bearing Ball 20 Bearing Needle 21 Gear Mainshaft 5th 22 Gear Mainshaft 2nd 23 Gear Mainshaft 3rd 24 Gear Mainshaft 1st 25 Gear Mainshaft 4th 26 Spacer 27 Mainshaft 28 Bearing 29 Ring Retaining 30 Seal 31 Retention Collar 32 TORX Screw 33 Ring Retaining 34 Nut Mainshaft 35 Washer Spring 36 Bushing 37 Bearing Closed Shifte...

Page 376: ...drel smaller than inside diameter of bearing and press countershaft free of access cover Slide mainshaft 1st gear 24 off mainshaft 8 See Figure 6 40 Remove beveled spacer 3 and coun tershaft 4th gear 4 11WARNING 1WARNING Retaining rings are highly compressed in the ring groove and may fly out with considerable force when pried out of the groove Always wear safety glasses or goggles while removing ...

Page 377: ...ith compressed air 2 Check gear teeth for damage If gears are pitted scored rounded cracked or chipped they should be replaced 3 Inspect the engaging dogs on the gears Replace the gears if dogs are rounded cracked battered chipped or dimpled 4 Discard all retaining rings that were removed ASSEMBLY CAUTION During assembly the split bearings 7 and the internal bores of the gears must be lubricated w...

Page 378: ...ext to washer 6 6 Locate countershaft first gear 8 Gear 8 has a radial groove at one side of the gear Install gear 8 over split bearing 7 with radial groove facing access door 7 Install thrust washer 6 and retaining ring 5 next to gear 8 8 Locate countershaft 4th gear 4 This flat shoulderless gear is splined and has a single radial groove at one side Position gear next to retaining ring 5 Place be...

Page 379: ...earing 7 16 Install mainshaft 2nd gear 22 onto shaft The shifter fork groove must face the access door 17 Install shouldered countershaft 5th gear 12 The single radial groove must face away from the access door 18 Expand retaining ring 5 and slide into groove next to countershaft 5th gear 12 19 See Figure 6 48 At outside of access door position retention collar 31 next to end of countershaft with ...

Page 380: ...the gear is pressed out against the resistance of the bearing inner race Without any support at the inner race the bearing is destroyed Whenever the main drive gear is removed the main drive gear bearing will also have to be replaced 5 At outside of case place driver 4 and thrust washer 5 over end of bolt 2 Install and tighten nut 6 until 5th gear 3 is free Figure 6 49 Main Drive Gear Assembly 1 M...

Page 381: ...Press in the inner bearing to a depth of 0 080 in 2 032 mm INSTALLATION 1 Replace main drive gear bearing See 6 11 ACCESS DOOR BEARINGS 2 See Figure 6 53 Use MAIN DRIVE GEAR REMOVER AND INSTALLER TOOL for assembly a Take bolt 2 and place washer 5 followed by main drive gear 4 over end of bolt b From inside of case insert bolt and main drive gear through inner race of ball bearing c Insert threaded...

Page 382: ...ing out of door from either side INSTALLATION Mainshaft and Countershaft Bearings 1 Lay access door on press with inside surface of door downward 2 Lay bearing squarely over bore with printed side of bear ing upward Place section of pipe or tubing slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder 3 Install new retain...

Page 383: ...ng is started in bore squarely Tighten nut 6 until bearing is seated against shoulder in bore 3 At outside of case install beveled retaining ring in groove inside bearing bore with beveled side facing outside of case 4 Lubricate bearing with SPORT TRANS FLUID Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in diameter 2 From the outside of the case place the needle b...

Page 384: ...taining ring 9 using SHIFT DRUM RETAINING RING INSTALLER Part No HD 39151 d Verify that retaining ring is fully engaged with drum groove 6 See Figure 6 59 Align shifter shaft a Place transmission in third gear b Place a No 32 drill bit 0 116 in dia through hole in detent plate 3 and between pawl 2 and drive pin at end of shifter drum shaft c Push down top of crank 4 to remove all clearance between...

Page 385: ...Install lockplate 4 over nut 3 so that two of lockplate s four drilled holes diagonally opposite align with sprocket s 2 two tapped holes NOTE The lockplate has four screw holes and can be turned to either side so you should be able to find a position without having to additionally tighten the nut If you cannot align the screw holes properly the nut may be additionally TIGHT ENED until the screw h...

Page 386: ...he original screws may be reused up to three times After the third removal installation cycle replace both screws with new screws identical to the original 14 Install the remaining removed components in the reverse order of the removal procedures See the procedures listed in the respective component sections 15 Adjust drive belt tension See 1 10 DRIVE BELT DEFLECTION 16 Fill transmission to proper...

Page 387: ...6 36 2002 Buell S3T Drive Transmission HOME NOTES ...

Page 388: ...Regulator 7 28 7 11 Battery 7 29 7 1 Headlamp 7 34 7 2 Tail Lamp 7 36 7 3 Turn Signals 7 37 7 4 Turn Signal Flasher 7 39 7 5 Handlebar Switches 7 40 7 6 Horn 7 42 7 7 Neutral Indicator Switch 7 43 7 8 Fuses and Circuit Breakers 7 44 7 9 Relay Block 7 45 7 10 Speedometer 7 46 7 11 Speedometer Sensor 7 48 7 12 Speedometer Performance Check 7 49 7 13 Tachometer 7 54 7 14 Tachometer Performance Check ...

Page 389: ......

Page 390: ... Instrument Fuse 15 Clock Odometer Fuse 15 BULB CHART LAMP DESCRIPTION BULBS REQUIRED WATTS AMPS PART NUMBER Headlamp High Low Replaceable Bulb 1 60 55 5 0 4 58 67969 96Y Position Lamp European models only 1 5 0 42 67968 96Y Marker Lamps Tail Stop Lamp 2 5 21 0 42 1 75 68075 94Y Turn Signal Lamp Front and Rear 1 Bulb per Lamp 4 10 0 83 68073 94Y Indicator Lamps on Instrument Support High Beam Indi...

Page 391: ...t lbs 4 7 Nm LOCTITE THREADLOCKER 243 blue Rotor Mounting Bolts 90 110 in lbs 10 12 Nm LOCTITE THREADLOCKER 243 blue Spark Plugs 11 18 ft lbs 15 24 Nm Starter Battery Positive Cable Nut 60 85 in lbs 7 10 Nm metric Stator Mounting Screws 30 40 in lbs 3 4 3 5 Nm T 27 TORX with retaining compound replace after removal Switchgear Housing Screws Left Side 25 33 in lbs 3 4 Nm metric Switchgear Housing S...

Page 392: ...ule has three primary functions First it computes the spark advance for proper ignition timing based on sensor input Second it controls the independent primary windings of the spark coil and is thus able to provide sequential and independent firing of the spark plugs non waste spark Third it calculates the correct air fuel ratio based on input from the sensors Figure 7 1 Ignition System Components...

Page 393: ...itoring the final com bustion efficiency in the exhaust system 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 The Bank Angle Sensor BAS provides input to the ECM on whether the vehicle lean is greater than 55 degrees As long as lean angle does no...

Page 394: ...itions and allows the rider to remove the key while leaving the lights on When the key is placed in the PARK position several indicator markers are or can be activated See Figure 7 5 REMOVAL 11WARNING 1WARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or serious injury 1 ...

Page 395: ...h face nut c Loosely install face nut 2 See Figure 7 6 Attach ignition key switch connector 33 to main wiring harness 3 Tighten face nut to secure switch within dash panel 4 Install negative battery cable to battery 5 Check ignition key switch for proper operation If opera tion fails reread procedure and verify that all steps were performed 6 Install front fairing mirrors and turn signals See the ...

Page 396: ...rk plugs 11 The high voltage discharge produces a spark to bridge the electrode gap of each spark plug The ignition coil fires each spark plug independently on the compression stroke of each cylinder REMOVAL 11WARNING 1WARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or ...

Page 397: ... insulation on the cables may be cracked or otherwise damaged allowing high tension current to short to metal parts This is most noticeable in wet weather or after the motorcycle has been washed INSTALLATION 1 Attach coil to frame with screws and washers Tighten to 4 6 ft lbs 5 8 Nm 2 See Figure 7 7 Attach connector 7 83 3 Connect front spark plug cable to connector 2 and rear spark plug cable to ...

Page 398: ...g on the cable will damage the cable s carbon core Disconnect spark plug cables from ignition coil and spark plug terminals Inspect all removed cables for damage INSPECTION 1 Inspect spark plug cables Replace cables that are worn or damaged a Check for cracks or loose terminals b Check for loose fit on ignition coil and spark plugs 2 Check cable boots caps for cracks or tears Replace boots caps th...

Page 399: ...l and grounding through the neutral switch By disengaging the clutch and grounding through the clutch lever switch Note that the ignition circuit allows operation in gear with the side stand extended if the clutch is disengaged However if the motorcycle is in gear with the side stand extended and the clutch is released the ignition ground is lost and the igni tion system is turned off This system ...

Page 400: ...s below correlate with the circled num bers in the 7 6 STARTER INTERLOCK flow charts 1 Check diode with an ohmmeter as shown in Figure 7 11 2 Check diode polarity as shown in Figure 7 11 Figure 7 8 Ohmmeter Diode Test Figure 7 9 Diode Polarity Continuity Infinite ohms b0643x4x b0644x4x TN TN GN Diode 1 Polarity TN GN TN W Diode 2 Polarity Figure 7 10 Diode Wiring TN W TN W Relay Block Diode 1 Diod...

Page 401: ...nd connector 60 Ground present Check for ground on BK wire of connector 60 Ground present YES Replace sidestand switch NO NO 5053 5054 5055 YES Repair open on TN GN wire YES Check Diode 1 with ohmmeter Diode OK Remove sprocket cover Check for ground at neutral switch terminal Ground present Check for ground on TN GN wire of Diode 1 Ground present Check for ground at TN wire on Diode 1 Ground prese...

Page 402: ...d present Check for ground on TN W wire of Diode 2 Ground present Check for ground on TN GN wire of Diode 2 Ground present YES Check Diode 2 with ohmmeter Diode OK YES Diode installed backwards Reverse polarity Replace diode YES Repair open on TN GN wire between connector 95 and Diode 2 NO Replace clutch switch Check for ground on BK wire of connector 95 Ground present NO NO NO Repair open on BK w...

Page 403: ...NGLE SENSOR 86 84 85 83 88 89 14 134 10 11 91 COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLOW LT LIGHT DIODE NO CONNECTION PIN CONNECTOR SOCKET CONNECTOR SPLICE CONNECTION CONNECTOR CODE TO GROUND FROM IGN RLY BK 1 2 BK TN GN R BE S1 95 CLUTCH SWITCH IGN MODULE FROM 2 GN BK W R IGN POWER BE 22 W BK W BK S8 1 3 2 4 GY O B R K R BR R K R ...

Page 404: ... The clutch switch attaches to the clutch con trol lever bracket The switch completes a path to ground for the ignition relay and the starter relay when the clutch is dis engaged Test the switch as follows 1 Unplug the 2 place clutch switch connector 95 2 Test the switch using an ohmmeter a With clutch engaged 1 switch open the switch should show ohms infinite ohms b With clutch disengaged 2 switc...

Page 405: ... 4 Replace the diodes by pulling them straight out The spare diode may be used in either circuit as long as it is installed in the correct direction Main Circuit Breaker See Figure 7 16 Attached to the frame above the battery the main circuit breaker 1 is between the ignition key switch and the battery Remove the main circuit breaker as follows 1 Remove seat and fuel tank See 4 36 FUEL TANK 2 Remo...

Page 406: ...ould result in death or serious injury 1 Disconnect negative battery cable from battery 2 Remove seat and tail section See 2 33 TAIL SECTION 3 Replace the diodes by pulling them straight out from relay block 4 Install new diode by plugging into slot on relay block 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shi...

Page 407: ...7 18 2002 Buell S3T Electrical HOME NOTES ...

Page 408: ...OOTING When the charging system fails to charge or does not charge at a satisfactory rate make the following recommended checks Battery Check for a weak or dead battery See 1 3 BATTERY Battery must be fully charged in order to perform any electrical tests Wiring Check for corroded or loose connections in the charging cir cuit See Figure 7 18 Voltage Regulator Inspection See Figure 7 18 The voltage...

Page 409: ... wired so they stay on at all times This condition could drain battery completely if vehicle is parked for a long time Check for this by con necting ammeter between negative battery terminal and battery 1 See Figure 7 21 Connect ammeter between negative battery terminal and battery With this arrangement you will also pick up any regulator drain 2 With ignition key switch turned to OFF and all ligh...

Page 410: ...ST Record measurement and compare with TOTAL CURRENT DRAW TEST before proceeding Inspect rotor Replace stator Perform AC OUTPUT TEST Replace regulator Perform VOLTAGE OUTPUT TEST Damaged or slipping rotor Perform CURRENT OUTPUT TEST System tests good up to this point Suspect 1 Accessories on for long periods when vehicle is parked and not running 2 Accessories on when vehicle is ridden very slowly...

Page 411: ...7 22 2002 Buell S3T Electrical HOME Figure 7 20 Charging System Circuit 30A BK BK BK S2 BK RD RD BK BK b0749chr Main Circuit Breaker Main Chassis Ground Starter Voltage Regulator 46 Battery ...

Page 412: ... engine at 2000 RPM 3 With ignition and all continuously running lights and accessories turned on headlamp on high beam read the total current draw 4 Compare this reading to the reading obtained after per forming the CURRENT AND VOLTAGE OUTPUT TEST a The current output should exceed current draw by 3 5 amps minimum b If output does not meet specifications there may be too many accessories for the ...

Page 413: ... is higher regulator is not functioning prop erly or connections are loose or dirty Stator Check 1 Turn ignition key switch to OFF 2 See Figure 7 24 Connect an ohmmeter a Locate voltage regulator connector 46 near the oil pump Disconnect from alternator stator wiring b Insert one ohmmeter lead into either stator socket c Attach the other lead to a suitable ground 3 Test for continuity with ohmmete...

Page 414: ...ts c Run the engine at 2000 RPM The AC output should be 38 52 volts AC 2 Compare test results to specifications a If the output is below specifications charging prob lem could be a faulty rotor or stator b If output is good charging problem might be faulty regulator rectifier Replace as required 3 Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST on page 5 24 Figure 7 26 Ch...

Page 415: ...r Press sprocket free of rotor NOTE Resistance to sprocket rotor disassembly is due in part to the magnetic force of the permanent rotor magnets Stator 1 See Figure 7 28 Disconnect stator wiring 4 from volt age regulator wiring at connector 5 46 near the oil pump 2 Remove cable straps holding stator wire to oil filter hose 3 Withdraw stator wiring 4 from behind the gearcase cover 4 Remove and disc...

Page 416: ...nkcase half Secure stator using four new TORX screws 2 Tighten screws to 30 40 in lbs 3 4 3 5 Nm 4 Route stator wiring 4 in front of starter behind gear case cover and outboard of oil pump 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 5 Connect alternator stator wiring to voltage regulator con nector...

Page 417: ...rmly grasping both connector halves Do not pull on leads or damage to the wires and or terminals may result 2 See Figure 7 30 Locate voltage regulator connector 46 near the oil pump Disconnect from alternator stator wir ing NOTE The black charging wire formerly loose is now part of the harness and connector 46 3 Remove screws and washers 4 Remove and discard voltage regulator 5 If necessary detach...

Page 418: ...12 6V charge the battery and then recheck the voltage after the battery has set for one to two hours If the voltage reading is 12 8V or above perform the load test Figure 7 32 Maintenance Free AGM Battery Table 1 3 Battery Electrolyte Antidotes CONTACT SOLUTION External Flush with water Internal Drink large quantities of milk or water fol lowed by milk of magnesia vegetable oil or beaten eggs Call...

Page 419: ...ns for the charger being used In addition to the manufacturer s instructions follow these general safety precautions Always wear proper eye face and hand protection Always charge batteries in a well ventilated area Turn the charger OFF before connecting the leads to the battery to avoid dangerous sparks Never try to charge a visibly damaged or frozen bat tery Connect the charger leads to the batte...

Page 420: ...le could be damaged 3 Connect the red battery charger lead to the positive terminal of the battery 4 Connect the black battery charger lead to the negative terminal of the battery NOTE If the battery is still in the vehicle connect the negative lead to the chassis ground Be sure that the ignition and all electri cal accessories are turned off 5 Step away from the battery and turn on the charger Se...

Page 421: ...ter leads to battery posts and place induction pickup over negative black cable See Figure 7 42 CAUTION To avoid load tester and or battery damage do not leave the load tester switch turned ON for more than 20 sec onds 4 Referencing Table 7 7 load battery at 50 of CCA rating using the load tester Voltage reading after 15 seconds should be 9 6V or more at 70 F 21 C 11WARNING 1WARNING Always turn th...

Page 422: ...t 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 8 Install seat See 2 35 SEAT STORAGE 11WARNING 1WARNING Always store batteries where they cannot be reached by children Contact with the battery s sulfuric acid could result in death or serious injury CAUT...

Page 423: ...m 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 1CAUTION The bulb contains Halogen gas under pressure Handle bulb carefully and wear eye protection Failure to comply may result in minor or moderate injury CAUTION Never touch the bulb with your fingers Fingerprints will etch the glass...

Page 424: ...ajor concern for motorcy clists Failure to have proper headlamp operation could result in death or serious injury 6 Check headlamp for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b See Figure 7 39 Check headlamp LOW 2 and HIGH beam 1 settings c Set headlamp to LOW beam 2 Press passing lamp switch 3 Headlamp should...

Page 425: ...ckwise to install 4 Install seat and tail section See 2 33 TAIL SECTION 5 Install tail lamp lens with two screws 1 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle see Step 6 Visibility is a major concern for motorcyclists Failure to have proper brake lamp opera tion could result in death or serious injury 6 Check tail lamp for proper operation If operation fails r...

Page 426: ...ullet connectors on turn signal wires as shown in Figure 7 42 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Failure to have proper turn signal operation could result in death or serious injury 3 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Activate left ...

Page 427: ...in death or serious injury 5 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Activate left turn signals using switch on left handle bar Front and rear left turn signals must flash c Activate right turn signals using switch on left han dlebar Front and rear right turn signals must flash d Turn ...

Page 428: ...result in death or serious injury 3 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Activate left turn signals using switch on left handle bar Front and rear left turn signals must flash c Activate right turn signals using switch on left han dlebar Front and rear right turn signals must flash ...

Page 429: ... 1 Remove three screws metric from handlebar switch 2 Separate switch housings and remove from handlebar 3 Remove seat 11WARNING 1WARNING The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gas before removing fuel tank Gasoline is extremely flammable ...

Page 430: ...ng to handlebar with three screws metric Tighten screws to 25 33 in lbs 3 4 Nm 2 Route switch housing wiring harness between front forks and along right side frame tube Attach connector 24 and if necessary connector 95 to wiring harness Fas ten wiring harness to frame with new cable straps 3 Install fuel tank See 4 36 FUEL TANK 11WARNING 1WARNING After installing seat pull upward on front of seat ...

Page 431: ...urn ignition key switch to OFF TROUBLESHOOTING 1 If the horn does not sound or fails to function satisfacto rily check for the following conditions a Discharged battery b Loose frayed or damaged wiring leading to horn ter minal 2 If battery has a satisfactory charge and wiring appears to be in good condition test horn grounds and switch using voltmeter a See Figure 7 50 Remove Y BK power 3 and BK ...

Page 432: ...COVER 6 Install the right fairing lower See 2 38 FAIRING LOW ERS REMOVAL INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 29 SPROCKET COVER 3 Remove the right fairing lower See 2 38 FAIRING LOW ERS 4 See Figure 7 52 Place transmission in first gear Remove two socket head screws 7 and lockplate 6 CAUTION Transmission sprocket nut has left hand thread...

Page 433: ...he tail section Circuit breakers prevent electrical overload of a circuit The circuit breaker electrical contacts remain closed completing the circuit as long as current amperage flowing through the circuit does not exceed the ampere rating of the breaker If the circuit current exceeds the breaker ampere rating then the circuit breaker contacts open and the current flow in the circuit is interrupt...

Page 434: ...ing is shown in Figure 7 56 Figure 7 55 Relay Block 1 Ignition Relay 2 Starter Relay 3 Starter Circuit Diode 4 Ignition Circuit Diode 5 Spare Diode 6 Mounting Tabs 6763 3 4 6 5 2 1 Figure 7 56 Relay Wiring TN W TN W Relay Block Diode 1 Diode 2 To Fuse Block Ignition Relay To Clutch Switch 95 TN GN TN Neutral Switch TN TN W To Side Stand Switch 60 W BK To Right Handle bar Switch 22 TN GN R BK To Ig...

Page 435: ...ng dash panel to front fairing bracket Pull dash panel upward but do not damage wiring 4 See Figure 7 57 Remove two nuts metric and lock washers 1 from speedometer cover 3 5 Slide speedometer cover 3 away from speedometer 6 See Figure 7 60 Remove wires from speedometer Pull lamp 5 from bore 7 Pull speedometer and attached odometer reset button from front of dash panel 8 Remove mounting gasket 9 If...

Page 436: ...sh panel a Feed wires through opening in speedometer cover b Using alcohol or window cleaner to lubricate rubber gasket slide speedometer into rubber mounting gasket c See Figure 7 60 Insert lamp 5 d Attach wires to speedometer as shown 5 See Figure 7 59 Install speedometer cover 3 a Place speedometer cover over speedometer Align posts on back of speedometer with holes in cover Drain hole must be ...

Page 437: ...ctor 65 to wiring harness 11WARNING 1WARNING 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 3 Install tail section and seat See 2 33 TAIL SECTION Figure 7 62 Speedometer Sensor 1 6991 2 1 Bolt 2 Speedometer Sens...

Page 438: ...is or repair It can also assist in determining if speedometer replacement is necessary Speedometer Operation Test 1 See Figure 7 65 Locate and disconnect the 3 place Deutsch connector 65 for the speedometer sensor Attach speedometer tester connector to speedometer sensor connector a Connector 65 is located above battery negative terminal 2 Place speedometer tester power switch in the ON posi tion ...

Page 439: ...ress 7 or 9 Speedometer Sensor Test If the speedometer is inoperative but backlighting and odom eter work the speedometer sensor may not be working See Figure 7 66 Fabricate a test harness using the following parts This harness can also be used to test the tachometer 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 e...

Page 440: ... and verify operation Does display toggle between trip and odometer modes YES Verify trip display consists of correct numbers Are correct numbers displayed NO Replace speedometer YES Go to Speedometer Test Chart 2A NO Remove boot over trip reset switch Toggle trip reset switch without boot Does display toggle between modes YES Unit OK Return to customer NO Place jump wire across leads to reset swi...

Page 441: ... on speedometer while moving shaking vehicle harness connections Output erratic YES Repair as necessary NO Replace speedometer NO Bad connection found Repair con nector or harness DIAGNOSTIC NOTES Low battery voltage on speedometer tester may cause inaccurate test results Make sure speedometer tester battery is fully charged If necessary remove speedometer sensor and check for accumulation of debr...

Page 442: ... for open wires Wires OK YES Replace speedometer NO Repair wires YES Check speedometer power O W wire and ground terminal BK wire voltage at back of speedometer Test voltage why shaking harness Does voltage flunctuate NO 4 6 VDC is not present Replace speedometer NO 4 6 VDC is present but no flunctuation to 0 1 VDC Replace speedometer sensor YES Repair as necessary NO Check for spark plug wire ter...

Page 443: ...age wiring 3 See Figure 7 68 Remove two nuts metric and lock washers 1 from tachometer cover 2 4 Slide tachometer cover 2 away from tachometer 5 See Figure 7 69 Remove wires from tachometer a Remove three lamps 1 2 and 3 and attached wires b Loosen screws and remove wires 4 5 and 6 6 Pull tachometer from front of dash panel 7 Remove rubber mounting gasket 8 If necessary replace tachometer wiring a...

Page 444: ... bores d Attach wires 4 5 6 to tachometer as shown 4 See Figure 7 68 Install tachometer cover 5 a Place tachometer cover over tachometer Align posts on back of tachometer with holes in tachome ter cover Drain hole must be at the bottom of cover b Apply LOCTITE THREADLOCKER 243 blue to both nuts metric c Fasten cover 2 to tachometer using two nuts met ric and lockwashers 1 5 See Figure 7 67 Positio...

Page 445: ...by moving its nee dle to the desired RPM b Test the tachometer at several different RPM read ings to verify proper operation NOTE All tachometer accuracy tolerances were taken at 68 77 F 20 25 C Sweep Test 1 See Figure 7 71 Connect the speedometer tester to the cam position sensor Deutsch socket housing 2 Place speedometer tester power switch in the ON posi tion Place signal switch in the OUT posi...

Page 446: ...ont fairing 2 See Figure 7 73 Unplug red wire 1 and black wire 2 3 Pull bulb housing 4 from back of clock 4 Remove two nuts and lockwashers 3 to free clock housing 6 from mounting bracket 5 5 From front of dash panel remove clock housing 6 INSTALLATION 1 See Figure 7 73 Slide clock housing 6 through front of dash panel 2 Place mounting bracket 5 on threaded shafts of clock housing 6 Secure with tw...

Page 447: ...7 58 2002 Buell S3T Electrical HOME NOTES ...

Page 448: ...86 GY O GY O TN W TN W GN TN GN GY TN W BK 1 2 SIDESTAND SWITCH BK W R BK TN GN TN SWITCH NEUTRAL R Y O W GN Y R Y R Y O W BK S2 S6 TO STOPLIGHT S8 ACC POWER BRAKE SWITCH 1 2 1 3 2 4 O W O W R Y R Y LOW BEAM LIGHT POWER HORN HIGH BEAM FROM FLASHER LEFT TURN HORN POWER S5 BE Y O W BN V BN Y BK W 1 3 5 6 7 8 9 RIGHT TURN W BN BK GN BE 2 O L BE GY S9 S4 W BK Y 2 3 4 O W 1 BN K B V HIGH BEAM LOW BEAM ...

Page 449: ...APPENDICES SUBJECT PAGE NO Appendix A Tools A 1 Appendix B Electrical Connectors B 1 Appendix C Metric Conversions C 1 Table Of Contents ...

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