Buell 2002 S3T, Service Manual

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4-98 2002 Buell S3T: Fuel System
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INSTALLATION
NOTE
The retention plates have decals on them showing the posi-
tion and direction that they are to be mounted. Also, they
have a V-shaped notch on the shorter straight side which
must face to the rear of the vehicle.
IMPORTANT NOTE
It is important that the prongs on the retention plate face
toward the rear of the vehicle and be in direct contact
with the fuel tank. All vehicles require two retention
plates, one above and one below the fuel tank.
1. See Figure 4-84. Carefully raise the back of the fuel tank
and place a mounting plate and a retention plate in posi-
tion on the frame. Make sure shorter straight side of both
retention plate and mounting plate face to rear of vehicle.
2. Carefully place the fuel tank onto the lower retention
plate.
NOTE
For motorcycles having a tank mask and/or tank bag as an
accessory, be sure to secure mask/bag so that it is between
the top retention plate and the mounting plate. The retention
plate teeth must be in direct contact with the fuel tank.
3. Place the remaining retention plate and mounting plate
in position on top of the fuel tank rear mounting projec-
tions. Make sure shorter straight side of both retention
plate and mounting plate face to rear of vehicle.
4. See Figure 4-84. Install mounting bolt and tighten to 18-
23 ft- lbs. (24-31 Nm).
5. Wait five minutes and tighten bolt again to 18-23 ft-lbs
(24-31 Nm).
CAUTION
Avoid pinching wiring harness and vent hose between
fuel tank and frame during tank installation. Pinched
hoses will negatively affect vehicle operation.
6. See Figure 4-84. Connect vent hose (13) to vent valve
fitting (11). Clamp hose to fitting with a new cable strap
(14).
7. Connect fuel hose to fuel outlet with a new clamp.
8. Attach 4-place fuel pump connector [86].
1 1
WARNING
1
WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
9. Install seat. See 2.35 SEAT
NOTE
Use a good quality unleaded gasoline (91 pump octane or
higher). Octane rating is usually found on the pump.
10. Fill fuel tank. Turn ignition key ON and listen for fuel
pump activation.
11. Carefully inspect for leaks. Perform fuel pressure test if
necessary.
FUEL TANK PRESSURE TEST
The fuel tank is a sealed, pressure-tested assembly when it
leaves the factory. If the fuel cap flange seal is broken the fuel
tank must be pressure tested as listed below before installa-
tion.
1. With fuel filter removed, gas cap installed and fuel vent
valve installed, spray soap and water solution around
fuel cap flange and fuel vent valve fitting.
2. Connect air hose to fuel vent valve. Shake the tank sev-
eral times to seat the ball in the vent valve.
NOTE
Fuel tank must be pressurized slowly or fuel vent will snap
shut and tank will not be pressurized. Slowly remove the fuel
cap when complete to verify that tank was pressurized during
test.
3. Slowly pressurize fuel tank to 3.3-4.3 psi (22.8-29.7
kPa). Check for air bubbles around fuel cap and flange.
4. Spray soap and water solution around two fittings on bot-
tom of fuel tank. Check for air bubbles around two fit-
tings.
5. Remove fuel cap from tank to make sure tank was pres-
surized.
6. Clean soap and water solution from fuel tank.
7. If bubbles were seen around fuel cap or flange, rework
gas cap or fuel tank and retest until no bubbles are
present when fuel tank is pressurized. If bubbles were
seen around fittings on bottom of fuel tank, tighten fit-
tings to specification. Reinstall fuel pump with new seals
if required. See
4.39 FUEL PUMP.