Buell 2002 S3T, Service Manual

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2002 Buell S3T: Maintenance 1-23
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ADJUSTMENT
Check clutch adjustment:
●
At the 500 mile (800 km) service interval.
●
At every 5000 mile (8000 km) service interval thereafter.
If clutch slips under load or drags when released, first check
control cable adjustment. If cable adjustment is within specifi-
cations, adjust clutch mechanism as described below.
When necessary, lubricate cable with LUBIT-8 TUFOIL
®
CHAIN AND CABLE LUBE (Part No. HD-94968-85TV).
1. Raise rear wheel off floor using REAR WHEEL SUP-
PORT STAND (Part No. B-41174).
2. See Figure 1-20. Slide rubber boot upward to expose
adjuster mechanism. Loosen jam nut from adjuster. Turn
adjuster to shorten cable housing until there is a large
amount of freeplay at clutch hand lever.
3. See Figure 1-21. Remove four TORX screws with wash-
ers (1) from clutch inspection cover (2). Remove clutch
inspection cover from primary cover. Do not damage or
dislodge Quad ring (3) from primary cover.
NOTE
Quad ring is shown removed from primary cover for illustra-
tive purposes only in
Figure 1-21.
4. Remove spring (4) and lockplate (5). Turn adjusting
screw (6) counterclockwise until it lightly bottoms.
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 1/16-1/8 in. (1.6-3.2 mm) freeplay at clutch hand
lever. Adjust as follows.
a. See Figure 1-22. Pull ferrule (1) (end of cable hous-
ing) away from bracket (2). Gap between ferrule and
bracket should be 1/16-1/8 in. (1.6-3.2 mm).
b. See Figure 1-20. Set freeplay by turning adjuster.
c. Tighten jam nut against adjuster.
d. Slide boot over cable adjuster mechanism.
7. Change or add transmission fluid if necessary.
8. See Figure 1-21. Install clutch inspection cover (2) using
four TORX screws with washers (1). Tighten in a cross-
wise pattern to 7-9 ft-lbs (10-12 Nm).
9. Check clutch cable freeplay. See Step 6 above.
Figure 1-20. Clutch Cable Adjuster Mechanism
Figure 1-21. Clutch Release Mechanism
Figure 1-22. Adjusting Clutch Freeplay
Rubber
Boot
Cable
End
Jam
Nut
Adjuster
1. TORX Screw with Washer
2. Clutch Inspection Cover
3. Quad Ring
4
5
1
2
3
6
4. Spring
5. Lockplate
6. Adjusting Screw
b0267x8x
b0289x6x
Bracket
Ferrule
0.0625-0.125 in.
(1.6-3.2 mm)