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2004 Buell P3: Drive/Transmission

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Figure 6-34. Transmission Assembly Left Crankcase Half

1.

Mainshaft nut

2.

Spring washer

3.

Retaining ring

4.

Bearing

5.

Left crankcase half

6.

Mainshaft

7.

Spacer

8.

Bearing (4)

9.

4th gear mainshaft

10. Thrust washer (6)
11. Retaining ring (7)
12. 1st gear mainshaft
13. 3rd gear mainshaft
14. 2nd gear mainshaft
15. Spacer
16. 4th gear countershaft
17. 1st gear countershaft
18. Countershaft
19. 3rd gear countershaft
20. 2nd gear countershaft
21. 5th gear countershaft
22. Bearing
23. Retaining ring
24. Countershaft retainer
25. Screw

a0126x6x

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Summary of Contents for Blast 2014

Page 1: ...04 BUELL P3 SERVICE MANUAL Part Number 99492 04Y 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: ...1 2 Edit Me Printed June 19 2003 1 24 pm ...

Page 3: ...o B 41174 2 Replacement Pad Part No B 41177 Front Fork Holding Tool Part No B 43933 Wheel Bearing Remover Installer Use with Part No HD 44060 Part No B 43982 Sprocket Locking Tool Part No B 43983 Main Drive Gear Cross Plate Used with Part No HD 35316A Part No B 43985 Transmission Remover Installer Part No B 43987 Engine Cradle Used with HD 42310 ...

Page 4: ... Part No HD 25070 Robinair Heat Gun Part No HD 33446A Cylinder Torque Plates and Torque Plate Bolts Part No HD 33446 86 Part No HD 33223 1 Cylinder Compression Gauge Part No HD 33413 A Carburetor Idle Adjustment Tool Part No HD 33416 Universal Driver Handle Part No HD 33418 Universal Puller Forcing Screw ...

Page 5: ...Part No HD 34643A Shoulderless Valve Guide Seal Installer Part No HD 34723 Valve Guide Hone 8 mm Part No HD 34731 Shoulderless Valve Guide Installation Tool Part No HD 34736B Valve Spring Compressor Part No HD 34740 Driver Handle and Remover Use with Part No HD 34643A and art No HD 34731 Part No HD 34751 Nylon Valve Guide Brush ...

Page 6: ...no bs 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 hsln...

Page 7: ...ackard 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 8: ...nstaller Part No HD 39301 A 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 Part No 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 9: ...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 Part No HD 39964 Reamer Lubricant Cool Tool Part No HD 39965 Deutsch Terminal Crimp Tool ...

Page 10: ...anizational System Part No HD 41137 Hose Clamp Pliers Part No HD 41155 VHS Video Shelf Part No HD 41183 Heat Shield Attachment Use with Part No HD 25070 Part No HD 41185 Hose Cutting Tool Part No HD 41185 1 Oil Hose Cutter Replacement Blade Part No HD 41405 Main Drive Gear Seal Installer ...

Page 11: ...art No HD 41675 Oil Pressure Sending Unit Wrench Part No HD 42310 Engine Transmission Stand Part No HD 42310 150 Drip Tray Use with Part No HD 42310 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 12: ...No HD 43646 Engine Stand Part No HD 43984 Crankshaft Locking Tool Part No HD 44358 Flywheel Support Fixture Part No HD 43682 10 Drip pan Use with Part No HD 43682 or Part No HD 43646 Part No HD 44069 Timkin Snap ring remover and installer Use with Part No HD 44404 Part No HD 44404 Timkin Bearing Remover Use with Part No HD 44069 ...

Page 13: ... Part No HD 94660 37B Mainshaft Locknut Wrench Use with Part No B 43982 Part No HD 94800 26A Connecting Rod Bushing Reamers and Pilots Part No HD 94803 67 Intake Camshaft Bushing Reamer Part No HD 94804 57 Rocker Arm Bushing Reamer Part No HD 94812 1 Pinion Shaft Bushing Reamer Use with Part No HD 94812 87 Part No HD 94812 87 Pinion Shaft Reamer Pilot Use with Part No HD 94812 1 ...

Page 14: ...with Part No HD 95635 46 Part No HD 95760 69A Bushing 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 Part No HD 33813 ...

Page 15: ... Part No HD 96710 40B Crankcase Main Bearing Lapping Tool Part No HD 96718 87 Pinion Bearing Outer Race Lapping Kit Part No HD 96796 47 Valve Spring Tester Part No HD 96921 52B Oil Pressure Gauge Part No HD 96921 58 Oil Pressure Gauge Adapter Use with Part No HD 96921 52B Part No HD 97087 65B Hose Clamp Pliers ...

Page 16: ...A 14 Appendix A Tools HOME Part No HD 97273 60 Camshaft Bushing Installer Part No HD 97292 61 Two Claw Puller Part No J 5586 Transmission Shaft Retaining Ring Pliers ...

Page 17: ...ace Packard Speedometer Indicators On back of speedometer 46 2 place barrel connector Voltage Regulator Above swingarm left side 60 2 place Amp Multilock Side Stand Switch On top of swingarm cable tied to rear brake line 61 9 slot fuse block Fuse Block Under seat on right side 65 3 place Deutsch Speed Sensor Under seat to right of shock 83 3 place Amp Multilock Ignition Coil Under frame backbone a...

Page 18: ...ches tightly closed NOTES The conical secondary locking wedge of the 3 pin con nector must be installed with the arrow pointing toward the external latch See Figure B 2 If the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its f...

Page 19: ...s 4 Strip lead removing 0 1562 in 4 0 mm of 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 ...

Page 20: ...terminal Figure B 7 a With the flat edge against the terminal insert the pick Snap On TT600 3 into the cavity until it stops b Pivot the end of the pick away from the terminal to release the tang c Gently tug on wire to pull terminal from chamber Do not tug on the wire until the tang is released or the terminal will be difficult to remove A click is heard if the tang is engaged but then inadverten...

Page 21: ... being the top of the connector 1 From the secondary lock side of the connector insert the terminal into its respective numbered chamber until it snaps in place For proper fit the slot in the terminal must face the tang in the chamber a If installing socket terminals see Figure B 6 b If installing pin terminals see Figure B 7 2 Gently tug on wire end to verify that the terminal is locked in place ...

Page 22: ... 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 8 Ins...

Page 23: ... F TO GND FROM STARTREL AY BK 2 IN TEGRATED ELE CTRONI C IGNI TION MODULE 131 120 121 1 2 3 4 6 5 TAIL STOP 128 30A A B C D KEY SW I TCH R GN B K 86 30 85 87 87A REL AY 33 TN W BK BK W SIDE STAND SW I TCH 1 2 65 60 123 86 30 85 87 87A SYSTEM REL AY FUSE BLOCK TOP VIE W 61 O LIG HTS 15A KEY SW I TCH SYSTEM 15A DIODE 1 DIODE 2 SPARE 15A IGNI T ION SPARE ACCESS ORY M ASTER C B RIG HTFRON T LAM P HEAD...

Page 24: ...WITCH 15A LIGHTS 61 TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 4 3 2 1 CLUTCH SWITCH 95 16 Y 16 GY 16 R 2 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B 6A RATING 6A RATING 16 R B C D A F E D C B A ON OFF PARK LOCK F E D C B A KEY SWITCH LOGIC TO BATT NEG MAIN CHASSIS GROUND 4 3 2 1 MASTER C B 123 START RELAY 87A 87 85 30 86 30A 128 START RELAY FROM TO GND BATTERY R BE BK 2 1 COLOR CODE B...

Page 25: ...arging R 1 R 1 BK BK R BK 3 BK 3 R 46 30A 128 BK 2 BK BK 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 a0278x7x ...

Page 26: ...D R BK BK R R BK KEY SWITCH R 2 D C B A 24 O Y BK GN HORN GY HORN POWER 122 BK HORN 9 2 8 7 6 5 4 3 1 R 7 5A 7 5A 7 5A 15A MASTER C B ACCESSORY SPARE IGNITION 15A SPARE DIODE 2 DIODE 1 15A SYSTEM KEY SWITCH 15A LIGHTS O R B 1 RELAY SYSTEM 87A 87 85 30 86 R R 1 BK R 1 R B 1 GN R 30A 128 TN Y 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 YELLO...

Page 27: ... 1 171 7 16 R 2 D A 7 5A 7 5A 7 5A 15A Y GY TO BATT NEG MAIN CHASSIS GROUND FLASHER MASTER C B ACCESSORY SPARE IGNITION 15A SPARE DIODE 2 DIODE 1 15A SYSTEM KEY SWITCH 15A LIGHTS 61 TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 33 K B GN R KEY SWITCH D C B A 30A 128 5 6 4 3 2 1 R Y O 39 38 24 9 2 8 7 6 5 4 3 1 9 2 8 7 6 5 4 3 1 O 16 Y 16 GY 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B 16 G...

Page 28: ...SS ORY M ASTER C B 1 2 3 4 M AINCHASSI SGROUND TO BATTNEG GY 1 2 3 4 5 6 AUTO ENRI CH THROTT LE POSI TION SENSOR K B LBE Y 15A 7 5A 7 5A 7 5A 95 CLUTCH SW I TCH 10 83 PK IGNM ODULE GN BK W R W BK W BK R W BK PK W BK V W K B BK TN Y V O FROM 3 R R R B 1 R 1 R 1 R GY GY V O O W V W V K B S14 22 TN Y R B 1 R R O SW I TCH NEUTRAL 131 TN R 2 R 2 R BK BK TN GN BK R BK R IGNPOW ER BE R BK1 TN TN W R 2 TN...

Page 29: ...67 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 15 16 1 1 1 16 1 1...

Page 30: ...id volume measurements in this Service Manual do not include the British Imperial Imp system equivalents The fol lowing conversions exist in the British Imperial system 1 pint Imp 20 fluid ounces Imp 1 quart Imp 2 pints Imp 1 gallon Imp 4 quarts Imp Although the same unit of measure terminology as the U S system is used in the British Imperial Imp system the actual volume of each British Imperial ...

Page 31: ...n Primary Fluid 1 19 1 12 Drive Belt and Rear Sprocket 1 21 1 13 Primary Chain 1 25 1 14 Rear Shock Absorber 1 26 1 15 Front Fork Oil 1 27 1 16 Steering Head Bearings 1 29 1 17 Spark Plug 1 31 1 18 Air Cleaner 1 32 1 19 Throttle Cables 1 34 1 20 Ignition Timing and Idle Speed Adjustment 1 35 1 21 Fuel Supply Valve and Filter Strainer 1 37 1 22 Starter Interlock and Electrical Switches 1 39 1 23 He...

Page 32: ...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 tools Protect yourself and bystanders with approved eye protection Don t just do the job do the job safely Removing Parts Always consider the weight of a part when lifting Use a hoist...

Page 33: ...res for removing and installing bearings Bearings do not usually need to be removed Only remove bearings if necessary Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with the bushing bore Use a bearing bushing driver or a bar with a smooth flat end Neve...

Page 34: ...ng hardened wire unless they were designed for that purpose Always cut at right angles Don t use any prybar as a chisel punch or hammer Hammers Never strike one hammer against a hardened object such as another hammer Always grasp a hammer handle firmly close to the end Strike the object with the full face of the hammer Never work with a hammer which has a loose head Discard hammer if face is chipp...

Page 35: ... Replace sockets showing cracks or wear Keep sockets clean Always use approved eye protection when using power or impact sockets Storage Units Don t open more than one loaded drawer at a time Close each drawer before opening up another Close lids and lock drawers and doors before moving storage units Don t pull on a tool cabinet push it in front of you Set the brakes on the locking casters after t...

Page 36: ...vice versa refer to the following Fluid ounces U S x 29 574 milliliters Pints U S x 0 473 liters Quarts U S x 0 946 liters Gallons U S x 3 785 liters Milliliters x 0 0338 fluid ounces U S Liters x 2 114 pints U S Liters x 1 057 quarts U S Liters x 0 264 gallons U S BRAKE FLUID 11WARNING 1WARNING D O T 4 brake fluid can cause irritation of eyes and skin and may be harmful if swallowed If large amou...

Page 37: ...ch control cables and hand lever and side stand L L L L L Lubricate and adjust steering head bearings X Check operation and throttle control I I I I I I I I I I I Inspect fuel valve lines and fittings for leaks I I I I I I I I I I I Clean fuel tank filter screen X Check operation of all electrical equipment switches including starter interlock I I I I I I I I I I I Check battery and clean connecti...

Page 38: ...fect molded in color panels If you are unsure of how to use this product see your Buell dealer Washing To wash molded in color panels follow the instructions below 1 Rinse surface with water 2 Wash with Harley Wash or Harley Sun Wash 3 Rinse surface thoroughly with water 4 Dry with a clean chamois or soft dry natural fiber cloth Cleaning Between Washings Untreated molded in color body panels somet...

Page 39: ...1 8 2004 Buell P3 Maintenance HOME NOTES ...

Page 40: ...ls or damage to the motorcycle electrical system will occur 11WARNING 1WARNING Always connect the positive battery cable first If the pos itive 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 CAUTION Overtightening bolts can damage battery terminals 2 See Figure 1 1 Insert bolt through b...

Page 41: ...kcase breather hose under severe service in warm or moderate tempera tures severe dust temperatures above 80o F 27o C exten sive idling or speeds in excess of 65 mph 105 km h extensive two up riding At 1000 mi 1600 km initial service and every 2500 mi 4000 km service interval thereafter NOTE Shorten oil change interval in cold weather Table 1 4 Recommended Engine Oils Harley Davidson Type Viscosit...

Page 42: ...on CAUTION Do not switch engine oil brands indiscriminately Some oils interact chemically when mixed Use of inferior oils or non detergent oils can damage the engine The motorcycle should be ridden for approximately 10 min utes to ensure oil is hot and engine is at normal operating temperature 1 The motorcycle must be in upright position and level not on sidestand with the engine OFF 2 See Figure ...

Page 43: ...ertighten 11 Place two drain hoses back on the hose fixture Install drain plugs to drain hoses and secure plugs with spring clamps 12 See Figure 1 2 Remove dipstick and refill with approxi mately 1 5 qts 1 419 5 ml recommended oil at filler hole See Table 1 1 13 Install dipstick and operate motorcycle for 10 minutes to reach normal operating temperature Check oil level again hot check and add oil ...

Page 44: ...quired Every 2 years Check rear brake pedal operation Before every ride At the 1000 mile 1600 km service interval At every 5000 mile 8000 km service interval thereafter Lubricate the front brake hand lever Every 5000 miles 8000 km FLUID LEVEL See Figure 1 5 With motorcycle in a level position check that brake fluid is between the upper and lower marks on front and rear reservoirs Add D O T 4 BRAKE...

Page 45: ...ront master cylinder cover Bring fluid level to within 0 125 in 3 2 mm of molded boss inside front master cylinder b Remove cap and gasket from rear master cylinder reservoir Bring fluid level to between upper and lower marks on reservoir 3 Depress release and then hold brake lever pedal to build up hydraulic pressure 4 Open bleeder valve metric about 1 2 turn counterclock wise brake fluid will fl...

Page 46: ...replace brake pads in pairs BRAKE ROTORS 11WARNING 1WARNING Do not allow brake fluid bearing grease or other lubri cants to contact brake rotor or reduced braking ability may occur which could result in death or serious injury Check front and rear brake rotors for minimum thickness At the 1000 mile 1600 km service interval At every scheduled service interval thereafter 1 Measure rotor thickness Re...

Page 47: ...l bearing At every 10 000 mile 16 000 km service interval Check wheel bearings for wear and corrosion Excessive play or roughness indicates worn bearings Replace bearings in sets only TIRE TREAD INSPECTION See Figure 1 11 Tread wear indicator bars will appear on tire tread surfaces when 1 32 inch or less of tire tread remains Arrows on tire sidewalls pinpoint location of wear bar indica tors Alway...

Page 48: ... freeplay at clutch hand lever 4 See Figure 1 13 Remove three TORX screws with washers 1 from clutch inspection cover 2 Remove clutch inspection cover from primary cover NOTE Quad ring removed from primary cover for illustrative pur poses only in Figure 1 13 5 Remove spring 4 and lockplate 5 Turn adjusting screw 6 counterclockwise until it lightly bottoms 6 Turn adjusting screw 6 clockwise 1 4 1 2...

Page 49: ...r boot over cable adjuster mechanism 9 Change or add transmission fluid if necessary NOTE Clean parts before re assembly and use a new gasket 10 See Figure 1 13 Install clutch inspection cover using three TORX screws with washers Tighten in a crosswise pattern to 84 108 in lbs 9 5 12 2 Nm 11 Check clutch cable freeplay See Step 6 above 12 Install left footpeg support bracket See 2 21 FOOT PEGS AND...

Page 50: ...ws with washers 1 from clutch inspection cover 2 Remove clutch inspection cover from primary cover 5 See Figure 1 16 Inspect fluid level with motorcycle in upright position 6 See Figure 1 15 Install clutch inspection cover using three TORX screws with washers Tighten in a crosswise pattern to 84 108 in lbs 9 5 12 2 Nm 7 Install left footpeg support bracket See 2 21 FOOT PEGS AND FOOTPEG SUPPORT BR...

Page 51: ...crews with washers 1 from clutch inspection cover 2 Remove clutch inspection cover from primary cover CAUTION Do not overfill the primary chaincase with lubricant Overfilling may cause rough clutch engagement incom plete disengagement clutch drag and or difficulty in find ing neutral at engine idle 8 See Figure 1 16 Add SPORT TRANS FLUID Part No 98854 96 quart size Part No 98855 96 gallon size as ...

Page 52: ...lace belt and drive sprocket that exceed maximum allowable deflection 11WARNING 1WARNING Check alignment of the rear wheel and or brake calipers when servicing motorcycle A misaligned rear wheel and or brake caliper could cause the rear brake disc to bind resulting in loss of control and death or serious injury Rear Sprocket 1 See Figure 1 18 Inspect each tooth of rear sprocket for a Major tooth d...

Page 53: ... CONDITION REQUIRED ACTION 1 Internal tooth cracks hairline OK to run but monitor condition 2 External tooth cracks Replace belt 3 Missing teeth Replace belt 4 Chipping not serious OK to run but monitor condition 5 Fuzzy edge cord OK to run but monitor condition 6 Hook wear Replace belt 7 Stone damage Replace belt if damage is on the edge 8 Bevel wear outboard edge only OK to run but monitor condi...

Page 54: ...ompressed air 13 Remove three TORX bolts washers and front sprocket cover from right side of motorcycle NOTE It may be necessary to compress suspension to gain access to front sprocket cover TORX bolt 14 Remove two TORX screws and washers from right side of rear inner fender Carefully bend rear inner fender upwards and remove drive belt Discard drive belt 15 Position new drive belt over transmissi...

Page 55: ...axle nut 24 Place screwdriver or rod through axle hole and torque rear axle nut to 48 52 ft lbs 65 1 70 5 Nm 25 Slide belt on sprocket teeth by rotating wheel to walk belt onto teeth 26 Lower motorcycle rear wheel 27 Connect negative battery cable to battery Tighten fas tener to 60 96 in lbs 6 8 10 9 Nm 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked i...

Page 56: ...ded at the first adjustment interval 1 See Figure 1 22 Back off jam nut 3 and chain limiting screw 1 2 Remove spacer 2 IMPORTANT NOTE Be certain to use Inch Pound Wrench Chain adjuster shoe can be damaged by excessive force 3 See Figure 1 24 Tighten chain limiting screw to 24 in lbs 2 7 Nm 4 Back off chain limiting screw 3 4 turn 4 1 2 flats 5 Hold chain limiting screw while tightening jam nut Fig...

Page 57: ...terioration At every 10 000 mile 16 000 km service interval NOTE See Figure 1 25 Damper component 3 cannot be serviced or repaired If the damper component is leaking or damaged it must be replaced Figure 1 25 Rear Shock Absorber Assembly 1 Bolt 2 Damper bushing 3 Damper component 4 Nut 5 Stopper ring 6 Spring seat 7 Spring 8 Spring seat stopper a0015xSx 1 2 3 4 1 2 4 5 7 8 6 ...

Page 58: ...ront fork holding tool part no B 41177 3 See Figure 1 27 Remove slider tube cap 4 See Figure 1 28 Push down on the B spring seat O ring included and remove the stopper ring and spring seat 5 See Figure 1 29 Remove the spring collar lower spring joint and spring from slider tube Figure 1 26 Clamping the Fork Figure 1 27 Slider Tube Cap 3767 3768 Figure 1 28 B Spring Seat Figure 1 29 Removing Sub As...

Page 59: ...wer spring joint and spring collar 9 Coat a new O ring with fork oil or sealing grease 10 Install new O ring onto spring seat 11 See Figure 1 31 Push down on spring seat past groove to install stopper ring Stopper ring will lock into groove when installed correctly 12 See Figure 1 32 Install slider tube cap 13 Install front forks See 2 17 FRONT FORK Figure 1 30 Pumping Fork Oil Figure 1 31 Compres...

Page 60: ...raps to frame tube behind steering neck Raise front wheel off floor using a floor hoist and lifting straps 4 Turn front wheel to full right lock 5 See Figure 1 33 Attach a spring scale into the hole in the front axle With scale 90 degrees from fork leg pull front wheel to center position It should take 6 5 7 lbs 2 9 3 2 kg to pull front wheel to center 6 Attach clutch cable to handlebar NOTE Check...

Page 61: ...ue to threads of fork stem and retighten cap nut to 28 32 ft lbs 38 43 Nm 7 Recheck tension using spring scale See Step 5 8 Tighten both lower triple clamp pinch screws 9 to 22 29 ft lbs 30 39 Nm 9 Tighten center cap pinch screw to 84 120 in lbs 10 14 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 ...

Page 62: ...f the elec trodes and is caused by an air fuel mixture that is too lean 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 bala...

Page 63: ...er 6 Remove remaining two allen head screws to free venturi ring from carburetor flange 7 Remove hex screw at bottom of air box 6 o clock posi tion to release bracket from crankcase hole 8 See Figure 1 37 Moving to left side of vehicle remove two flange bolts to release side of air box from triangular shaped bracket Do not remove bottom bolt to crank case CAUTION Do not take bolt in and out of the...

Page 64: ...ially installed push clean air inlet hose onto middle fitting of 3 way connector 3 Moving to opposite side of vehicle apply a small dab of Loctite Low Strength 222 Purple to threads of two flange bolts Slide bolts through top two holes of triangu lar bracket and install into left side of air box Alternately tighten screws to 36 60 in lbs 4 1 6 8 Nm 4 Returning to right side of vehicle align slots ...

Page 65: ...t 5 off cable adjuster 2 2 Loosen cable adjuster lock 1 on each adjuster 3 Turn adjusters 2 in direction which will shorten cable housings to minimum length 4 Point front wheel straight ahead Twist throttle control grip to fully open position hold in position 5 Turn adjuster on throttle control cable 3 until throttle cam stop touches carburetor stop plate Tighten adjuster lock on throttle control ...

Page 66: ... in running engine with too much spark advance and may cause extreme engine knock and engine failure 6 See Figure 1 41 Timing light will flash each time an igni tion system spark occurs Aim timing light into timing inspection hole The advance timing mark two dots should be centered in timing inspection hole If this is the case ignition timing is properly adjusted Go to Step 11 If timing mark is no...

Page 67: ...here are variations in individ ual components it is possible for a properly warmed up engine to idle at 2000 RPM 2 See Figure 1 44 The ignition coil cable is located on the left side of the bike behind the fuel supply valve With the bike running place hand held tachometer on ignition coil cable 3 Press the tachometer button to obtain a reading for the current RPM 4 See Figure 1 43 Set engine speed...

Page 68: ... battery negative terminal 3 Drain fuel tank as follows a See Figure 1 45 Rotate handle on the fuel supply valve to the fully vertical position 4 of to shut the gasoline supply to the carburetor OFF 11WARNING 1WARNING Some gasoline will drain from the outlet hose when dis connected from the fuel valve Thoroughly wipe up any spilt fuel immediately Dispose of rags in a suitable man ner Gasoline is e...

Page 69: ...n flange of fuel valve assembly 3 Insert fuel valve assembly into fuel tank bore and install two allen head screws Alternately tighten screws to 6 10 in lbs 0 7 1 1 Nm 4 Push hose onto outlet fitting at side of fuel valve Turn slotted screw to tighten band clamp 5 Verify that handle of fuel supply valve is in the OFF position and fill the fuel tank 6 Rotate handle of fuel supply valve to ON and ca...

Page 70: ...onditions must exist to allow operation of the vehicle Clutch disengaged lever pulled in must be done when ever starting motorcycle Transmission in neutral Sidestand retracted If the motorcycle starts and operates without any of the three conditions being met see 7 11 STARTER IGNITION INTER LOCK for troubleshooting procedures TESTING SWITCHES Check the following electric switches for proper operat...

Page 71: ...ycle seat Weight of rider will compress vehicle suspension slightly 6 Stand motorcycle upright 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 proper height alignment Main beam of light broad flat pattern of light should be cen tered on horizont...

Page 72: ... 16 Nm Brake banjo bolts 16 20 ft lbs 22 27 Nm Front brake caliper mounting bolts 18 22 ft lbs 24 30 Nm Rear large brake caliper mounting bolt 18 22 ft lbs 24 30 Nm Rear small brake caliper mounting bolt 14 5 18 ft lbs 20 24 Nm Brake caliper pin 132 174 in lbs 15 20 Nm Front rotor TORX screws 24 27 ft lbs 33 37 Nm Rear rotor TORX screws 24 27 ft lbs 33 37 Nm Front axle nut 38 42 ft lbs 52 57 Nm Re...

Page 73: ...lug or turn off battery charger before con necting or disconnecting charger clamps at battery Con necting or disconnecting clamps with charger on could cause a spark and a possible battery explosion A battery explosion may rupture the battery case and spray sulfu ric acid onto the surrounding area and personnel which could result in death or serious injury 11WARNING 1WARNING Store battery out of r...

Page 74: ...ule 5 Carburetor controls not adjusted correctly 6 Ignition coil not functioning 7 Engine oil too heavy winter operation 8 Ignition not timed properly 9 Fuel tank filler cap vent plugged or carburetor fuel line closed off restricting fuel flow 10 Water or dirt in fuel system and carburetor 11 Enrichener valve inoperative 12 Air leak at intake manifold 13 Valves sticking Starts But Runs Irregularly...

Page 75: ...oil return line to reservoir 4 Restricted breather passage s to air cleaner ELECTRICAL 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 functio...

Page 76: ...front nut to 38 42 ft lbs 51 5 56 94 Nm Tighten rear nut to 48 52 ft lbs 65 70 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 5 64 in 2 0 mm 6 Rims and tires out of round or eccentric with hub tire runout should not be more than 3 32 in 2 4 mm 7 Irregular or peaked front tire t...

Page 77: ...1 46 2004 Buell P3 Maintenance HOME NOTES ...

Page 78: ...Rear Brake Master Cylinder 2 32 2 14 Rear Brake Caliper 2 37 2 15 Rear Shock Absorber 2 41 2 16 Throttle Control 2 42 2 17 Front Fork 2 43 2 18 Fork Stem And Bracket Assembly 2 54 2 19 Swingarm 2 56 2 20 Exhaust System 2 57 2 21 Footpeg Support Brackets 2 59 2 22 Sprocket Cover 2 60 2 23 Fenders 2 61 2 24 Lower Belt Guard 2 63 2 25 Tail Section And Rear Frame Assembly 2 64 2 26 Windscreen 2 66 2 2...

Page 79: ......

Page 80: ...th or serious injury Table 2 1 Chassis Specifications DIMENSIONS IN MM Wheel Base 55 30 1404 Seat Height Low Seat High Seat 25 50 27 50 648 698 Road Clearance 5 10 129 5 Trail 3 4 86 Rake 25 Table 2 2 Weight Specifications WEIGHT U S MODELS LBS KG Wet Weight 380 172 GVWR 780 353 GAWR Front 280 127 GAWR Rear 500 226 Load Capacity 400 181 Table 2 3 Fluid Capacities CAPACITIES U S Metric Fuel Tank To...

Page 81: ...e 2 25 Front brake line clamp screw 36 60 in lbs 4 7 Nm Page 2 31 Front brake switch screw 7 13 in lbs 0 8 1 5 Nm Page 2 25 Front fender mounting screws 27 30 in lbs 3 1 3 4 Nm Page 2 61 Front isolator mount bolt 63 70 ft lbs 85 95 Nm Page 2 71 Front muffler bolts 22 25 ft lbs 30 34 Nm Page 2 58 Front sprocket cover bolts 30 36 in lbs 3 4 Nm Page 2 60 Front tie bar bolt 30 33 ft lbs 41 45 Nm Page ...

Page 82: ... drops of LOCTITE 243 to last few threads metric Page 2 35 Rear muffler strap bolts 22 25 ft lbs 30 34 Nm Page 2 58 Rear shock top and bottom bolt 35 40 ft lbs 47 54 Nm Page 2 41 Steering head upper triple tree clamp screws at sliders 13 16 ft lbs 18 22 Nm LOCTITE ANTI SEIZE Page 2 53 Swingarm bolt 24 26 ft lbs 33 35 Nm Apply anti seize to bolt and install Page 2 56 Swingarm pinch bolt 17 19 ft lb...

Page 83: ...n the sidewall Rim size and contour are marked on the rim s exterior surface Example MT 2 5 x 16 0 DOT MT designates the rim contour 2 5 is the width of the bead seat measured in inches 16 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 Table 2 5 Table 2 5 Tire Fi...

Page 84: ...n Number when ordering parts or making inquiries about your Buell motorcycle Figure 2 1 Vehicle Identification Numbers V I N Sample V I N as it appears on the steering head 4MZKP13C743500015 Sample abbreviated V I N as it appears on the left side crankcase KP134500015 13 World 58 California Manufacturer Buell Motorcycle Company Engine 500001 520000 World 520001 525000 CA Type Designation Buell Bla...

Page 85: ...2 ft lbs 52 57 Nm Tighten rear axle nut metric to 48 52 ft lbs 65 71 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 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 9 TIRES Rims and tires out of round or ecc...

Page 86: ...ome 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 128 km h In emergency situations if a temporary repair is made ride slowly with as light of a load as possible until the tire is permanently repaired or repla...

Page 87: ...eel and then pulling away from rotor NOTE Do not operate front brake lever with front wheel removed or caliper pistons may be forced out Reseating pistons requires caliper disassembly 5 See Figure 2 5 Insert screwdriver rod through axle hole 1 Loosen front axle nut 4 6 Loosen pinch screw 2 7 Remove front axle nut spacer and washer Pull front axle out of wheel hub while supporting front wheel Figur...

Page 88: ...t brake rotor and pads 11WARNING 1WARNING Always replace brake pads in complete sets for correct brake operation Never replace just one brake pad Fail ure to install brake pads as a set could result in death or serious injury Figure 2 6 Front Wheel Assembly a0161a2x 1 4 2 9 12 10 3 5 6 8 7 1 Nut metric 2 Left axle spacer 3 Wheel bearing 4 Wheel 5 Valve stem 6 Wheel weight 7 Axle spacer center 8 Wh...

Page 89: ...RES 3 Verify that wheel and tire are true See 2 8 CHECKING CAST RIM RUNOUT 4 Balance tire See 2 9 TIRES ADJUSTMENT INSTALLATION 1 See Figure 2 6 Install front axle a Position wheel between forks with brake rotor on gearcase side of motor b With pinch screw metric loose insert threaded end of axle through right side fork c Push axle through fork and wheel hub until axle begins to emerge from left s...

Page 90: ... slide belt off DISASSEMBLY 1 See Figure 2 8 Remove and discard five sprocket bolts 6 from sprocket cover 2 Remove sprocket cover 7 from sprocket 3 Remove and discard hardened washers from sprocket 4 Remove sprocket from rear wheel 5 Remove five T40 TORX screws and brake rotor from rear wheel CLEANING AND INSPECTION 1 Thoroughly clean all parts in solvent 2 Inspect all parts for damage or excessiv...

Page 91: ...cle which could result in death or serious injury 3 Place new hardened washers on sprocket 4 Position sprocket cover over washers and install to sprocket with five new sprocket bolts Tighten sprocket bolts to 18 22 ft lbs 24 30 Nm 5 See Figure 2 9 Install brake rotor 9 to wheel a Verify that the brake rotor is thoroughly clean b Apply LOCTITE 272 red to threads of each of the five T40 TORX screws ...

Page 92: ... rotor 3 Slide axle through washer swing arm carrier left side spacer and wheel assembly a See Figure 2 11 Hold right side spacer in place b Insert axle through right side spacer and swingarm c Install flat washer lockwasher and axle nut 4 Place screwdriver or rod through axle hole and torque rear axle nut to 48 52 ft lbs 65 71 Nm 5 Slide belt on sprocket teeth by rotating wheel to walk belt onto ...

Page 93: ...nd replace both wheel bear ings REMOVAL 1 Remove wheel from motorcycle See 2 6 REAR WHEEL 2 See Figure 2 13 Obtain WHEEL BEARING INSTALLER REMOVER Part No B 43933 and assemble a Sparingly apply graphite lubricant to threads of forc ing screw 1 to prolong service life and ensure smooth operation b Install nut 2 washer 3 and Nice bearing 4 on screw Insert assembly through hole in bridge 5 c Drop bal...

Page 94: ...threaded rod to prolong service life and ensure smooth operation b See Figure 2 15 Place threaded rod through sup port plate Insert assembly through wheel c See Figure 2 16 Place the new bearing 6 on rod 1 with lettered side outward d Install pilot 5 Nice bearing 4 washer 3 and nut 2 over rod 2 Hold hex end of threaded rod 1 and turn nut 2 to install bearing 6 Bearing will be fully seated when nut...

Page 95: ...l Part No 12547 3 Forcing screw Part No HD 44060 4 4 Nut Part No 10210 5 Washer Part No 12004 6 Nice bearing Part No RS25100 200 7 Lubricant Part No J 23444A 8 Collet 3 4 in Part No B 43993 3 9 Collet 1 0 in Part No B 43993 7 10 Pilot 3 4 in Part No B 43993 6 11 Pilot 1 0 in Part No B 43993 8 12 Support plate pilot Part No B 43993 1 13 Threaded rod pilot Part No 280856 ...

Page 96: ...ation shown in Table 2 7 Rim Radial Runout 1 See Figure 2 19 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 7 Table 2 7 Cast Wheel Runout MEASUREMENT in mm MAXIMUM LATERAL RUNOUT 0 040 1 02 MAX...

Page 97: ...o heed this warning could result in death or serious injury 11WARNING 1WARNING Tubeless tires may be repaired in the tread area only and then the puncture must be 1 4 inch 6 4 mm or smaller Never repair a tire with less than 1 16 inch 1 6 mm tread depth All repairs must be made from inside the tire Use of faulty or defective tires can adversely affect handling and lead to loss of vehicle control w...

Page 98: ...onto jaws of tire machine Lubricate tire bead with soap solution 6 Fit wedge over rim of wheel 7 Pull bead up over rim in one spot and fit bead to wedge Spin wheel to draw full length of bead over rim and off wheel Do not use excessive force when starting bead over rim CAUTION Follow the tire machine manufacture s recommendation for the correct placement of the bead on the mandrel Incorrect mounti...

Page 99: ...aced Place rubber grommet on valve stem with shoulder in recess of the valve stem head 2 Install and tighten nut to 42 44 in lbs 4 7 5 0 Nm 3 Thoroughly lubricate bead on both sides of tire with a rubber lubricant Lubricate inside diameter of bead and side wall Lubricate rim flanges and safety hump on wheel 11WARNING 1WARNING Read the operating manual for the manufacturer and model of tire machine...

Page 100: ...0 will produce satisfactory results However dynamic balancing utilizing a wheel spinner can be used to produce finer tolerances for better high speed handling characteristics Follow the instruc tions supplied with the balance machine you are using WEIGHTS FOR CAST WHEELS The maximum weight permissible to accomplish balance is 1 0 oz 28 g total weight applied to the front wheel 2 0 oz 56 g total we...

Page 101: ...ar CAUTION Damaged banjo bolt seating surfaces will leak when reassembled Prevent damage to seating surfaces by carefully removing brake line components 3 See Figure 2 27 Remove banjo bolt 6 metric and two banjo washers 4 to disconnect brake line 5 from mas ter cylinder Discard banjo washers 4 Unplug both terminals to detach brake lamp switch NOTE The individual parts of the brake lamp switch are ...

Page 102: ...ch 4 See Figure 2 30 Compress piston 2 and remove rub ber boot 1 5 Depress piston assembly and remove internal snap ring 3 Discard snap ring 6 See Figure 2 31 Remove piston assembly 1 4 from front master cylinder Figure 2 28 Hand Lever Figure 2 29 Front Brake Switch 6488 2 3 1 1 Nut metric 2 Pivot bolt 3 Hand lever 3 1 2 1 Screw lockwasher and washer 2 Tang 3 Front brake switch 6489 Figure 2 30 Sn...

Page 103: ...er solvents Wipe dry with a clean lint free cloth Blow out drilled passages and bore with a clean air supply Do not use a wire or similar instrument to clean drilled pas sages in bottom of reservoir 2 Carefully inspect all parts for wear or damage and replace as necessary 3 Inspect piston bore in master cylinder housing for scor ing pitting or corrosion Replace housing if any of these conditions a...

Page 104: ...le in master cylinder assembly b Lubricate pivot bolt 2 with LOCTITE ANTI SEIZE c Install pivot bolt through top of assembly Tighten to 4 13 in lbs 0 5 1 5 Nm d Install nut 1 metric Tighten to 44 62 in lbs 5 7 Nm 5 See Figure 2 29 Install front brake lamp switch 7 a Attach front brake switch with screw washer and lockwasher 1 Tighten to 7 13 in lbs 0 8 1 5 Nm b See Figure 2 34 Test switch action T...

Page 105: ...boss inside front master cylinder reservoir 11WARNING 1WARNING Verify proper operation of the master cylinder relief port A plugged or covered relief port can cause brake drag or lockup which could result in loss of vehicle control and death or serious injury 7 See Figure 2 36 Verify proper operation of the master cylinder relief port 8 Actuate the brake lever with the reservoir cover removed A sl...

Page 106: ... banjo washers 4 to disconnect brake line 1 from cali per Discard banjo washers 3 Remove brake pads a Remove pin plug 5 b See Figure 2 38 Remove pad hanger pin 1 met ric c Remove brake pads from caliper 4 See Figure 2 37 Detach caliper from mounts a Remove lower mounting screw 6 b Remove upper mounting screw 6 and brake line wireform 7 while supporting caliper above brake rotor c Slowly remove cal...

Page 107: ...cloth Blow out drilled passages and bore with a clean air supply Do not use a wire or similar instrument to clean drilled pas sages 2 Carefully inspect all components Replace any parts that appear damaged or worn Do not hone caliper piston bore 3 Inspect brake rotor a Measure rotor thickness Replace if minimum thick ness is less than 0 180 in 4 5 mm b Check rotor surface Replace if warped or badly...

Page 108: ...G 1WARNING Use only new black 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 CAUTION To avoid leakage verify that banjo washers banjo bolt hydrauli...

Page 109: ...oir cover removed A slight spurt of fluid will break the surface if all internal components are working properly 9 See Figure 2 43 Install master cylinder cover 1 and cover gasket with two screws 2 Tighten to 9 13 in lbs 1 0 1 5 Nm 10 Depress front brake lever several times to set brake pads to proper operating position within caliper Bleed brake system 11WARNING 1WARNING Check for proper brake la...

Page 110: ...or serious injury CAUTION To avoid leakage ensure that banjo washers banjo bolt hydraulic brake line and master cylinder bore are com pletely clean 1 See Figure 2 44 Connect brake line to master cylinder using two new banjo washers 2 and banjo bolt 1 met ric Loosely install bolt into master cylinder 2 From the master cylinder the brake line runs downward in front of the right handlebar where it tu...

Page 111: ...banjo bolt surfaces will leak when reassem bled Prevent damage to seating surfaces by carefully removing brake line components 2 See Figure 2 46 Remove banjo bolt 3 metric and two banjo washers 4 to detach brake line 2 from master cylinder 5 Discard banjo washers 3 Disconnect push rod 9 from brake pedal clevis 13 a Spin locknut 12 away from top surface of clevis b Turn rod assembly 9 to free rod f...

Page 112: ...it upon assembly 1 See Figure 2 49 Slide rubber boot on rod assembly 3 away from master cylinder body 1 2 Depress rod assembly 3 and remove internal snap ring 2 Discard snap ring 3 Remove piston assembly 4 from master cylinder body Figure 2 47 Master Cylinder Mounting Figure 2 48 Remote Reservoir 7704 2 2 1 1 Banjo bolt metric 2 Screw 2 metric 3 Spacers 4 Rubber boot 5 Rod adjuster 6 Locknut 7 Cle...

Page 113: ...to protect seating surfaces a Examine walls of master cylinder reservoir for scratches and grooves Replace if damaged b Verify that vent holes on master cylinder are com pletely open and free of dirt or debris 2 Inspect boot on front of master cylinder for cuts tears or general deterioration Replace if necessary ASSEMBLY 1 See Figure 2 50 Insert piston assembly 4 spring first into master cylinder ...

Page 114: ...w black 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 To avoid leakage after assembly verify that banjo wash ers banjo bolt hyd...

Page 115: ...ke 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 Visibility is a major concern for motorcy clists Failure to have proper brake lamp could result in death or serious injury 8 Turn ignition key switch to IGN Apply rear brake...

Page 116: ... and large screw 7 metric to detach caliper from mount 4 See Figure 2 55 Remove clip 1 from rear caliper mount 2 if necessary DISASSEMBLY 1 See Figure 2 54 Remove pin plug and pad hanger 5 metric to free brake pads 2 See Figure 2 55 Remove clip 1 from caliper body 3 See Figure 2 56 Remove piston 3 using BRAKE CALI PER PISTON REMOVER 1 Part No B 42887 with adaptor 2 4 Remove two o rings from groove...

Page 117: ...1WARNING 1WARNING Always replace brake pads in complete sets for correct brake operation Never replace just one brake pad Fail ure to install brake pads as a set could result in death or serious injury 4 Inspect brake pads for damage or excessive wear Replace both pads as a set if the friction material of either pad is worn to 0 040 in 1 0 mm or less ASSEMBLY 1 See Figure 2 57 Place clip 1 inside ...

Page 118: ...Tighten to 16 20 ft lbs 22 27 Nm 4 Depress rear brake pedal several times to set brake pads to proper operating position within caliper Bleed brake system 5 Verify proper fluid level in reservoir 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper brake lamp operation could result in death or seri...

Page 119: ...n pads Replace brake pads Loose mounting bolts Tighten bolts Warped rotor Replace rotor Ineffective brake lever pedal travels to limit Low fluid level Fill master cylinder with approved brake fluid and bleed system Piston cup not functioning Rebuild cylinder Ineffective brake lever pedal travel normal Distorted or glazed rotor Replace rotor Distorted glazed or contaminated brake pads Replace pads ...

Page 120: ... the bottom mount 7 Remove shock absorber assembly INSTALLATION 1 See Figure 2 60 Place new damper bushings 2 into mounting holes of shock absorber if not installed 2 Loosely install bottom bolt and nut 3 Loosely install top bolt and nut NOTE Torque bolts and nuts from the bolt side only 4 Tighten bottom bolt to 35 40 ft lbs 47 54 Nm 5 Tighten top bolt to 35 40 ft lbs 47 54 Nm 11WARNING 1WARNING A...

Page 121: ...ld result in death or serious injury Clean all parts in a non flammable cleaning solvent Blow dry with compressed air Replace cables if frayed kinked or bent ASSEMBLY INSTALLATION 1 Route cables as noted in 8 2 Connect cables at carburetor 3 Attach throttle cable clamp Use LOCTITE 222 purple on screw 4 See Figure 2 62 Position ferrules on cable wheel 5 Insert idle control into front switch housing...

Page 122: ...l filled damping mechanism controls the telescoping action of each tube slider assembly Figure 2 63 Front Fork Assembly a0073xSx 12 13 14 15 16 17 18 19 11 1 2 3 4 5 6 8 9 20 21 7 22 10 1 Slider tube cap 2 Stopper ring 3 Spring seat 4 O ring 5 Spring collar 6 Lower spring joint 7 Spring 8 Damper assembly 9 Lock piece 10 Rebound spring 11 Slide bushing 12 Dust seal 13 Retaining ring 14 Oil seal spa...

Page 123: ...e front fender See 2 23 FENDERS 5 See Figure 2 64 Loosen headlamp bracket screws 6 See Figure 2 65 Loosen the large pinch screws on both the upper and lower triple clamps 7 See Figure 2 66 Remove front fork Repeat procedure for the other front fork Figure 2 64 Headlamp Bracket Screws Figure 2 65 Upper and Lower Triple Clamp Pinch Screws a0065aSx 3765 Figure 2 66 Front Fork Removal 3766 ...

Page 124: ...cap 4 See Figure 2 69 Push down on the spring seat o ring included and remove the stopper ring and spring seat 5 See Figure 2 70 Remove the spring collar lower spring joint and spring from slider tube Figure 2 67 Clamping the Fork Figure 2 68 Slider Tube Cap 3767 3768 Figure 2 69 Spring Seat Figure 2 70 Removing Sub Assembly 3769 1 Spring collar 2 Lower spring joint 3 Spring a0006xSx 1 2 3 ...

Page 125: ... until the tube moves freely 7 See Figure 2 72 Remove the center bolt metric from the bottom of the fork tube 8 See Figure 2 73 Remove the damper assembly lock piece and the rebound spring from the slider tube Figure 2 71 Pumping Fork Oil Figure 2 72 Removing Center Bolt 3770 3771 Figure 2 73 Removing Damper 3772 ...

Page 126: ...g ring from the slider assembly and the slider tube 10 See Figure 2 75 Pull the slider tube out of the slider assembly Remove oil seal back up ring and guide bush ing 11 See Figure 2 76 Remove the slide bushing by prying the slide bushing at the split Figure 2 74 Removing Dust Seal Figure 2 75 Removing Slider Tube 3775 3773 1 Oil seal 2 Back up ring 3 Guide bushing 3 2 1 Figure 2 76 Removing Slide...

Page 127: ...es Replace if damaged or worn 4 Replace the retaining ring if distorted 5 Measure spring free length Replace springs shorter than service wear limit of 12 8 in 325 mm 6 Measure rebound spring free length Replace springs shorter than service wear limit of 0 69 in 17 4 mm 7 See Figure 2 78 Measure slider tube runout Replace slider tube if runout exceeds the service wear limit of 0 008 in 0 2 mm Figu...

Page 128: ... Figure 2 80 Install damper assembly and rebound spring into slider tube 4 See Figure 2 81 Install lock piece into damper 5 See Figure 2 82 Clamp the slider assembly in a vise with front fork holding tool Part No B 41177 Figure 2 79 Install Slide Bushing Figure 2 80 Damper Assembly 3782 3794 Figure 2 81 Lock Piece Figure 2 82 Clamping the Slider Assembly 3791 3792 ...

Page 129: ...y to prevent damage to bushings and seals 7 See Figure 2 84 Install spring onto damper assembly 8 See Figure 2 85 Install center bolt and washer 9 Coat the guide bushing with fork oil or sealing grease 10 See Figure 2 86 Install guide bushing onto the slider tube Figure 2 83 Installing Slider Tube Figure 2 84 Install Rebound Spring 3790 3796 Figure 2 85 Install Center Bolt Figure 2 86 Install Guid...

Page 130: ...seal spacer and backup ring 14 See Figure 2 89 Using FORK SEAL DRIVER Part No B 43991 drive the guide bushing with the oil seal spacer and oil seal into position in the slider assembly 15 See Figure 2 90 Install retaining ring Verify ring is installed securely in the groove inside slider assembly Figure 2 87 Slider Tube Protection Figure 2 88 Oil Seal and Backup Ring 3781 3785 Figure 2 89 Fork Sea...

Page 131: ... with fork oil or sealing grease 21 Install new o ring onto spring seat 22 See Figure 2 93 Push down on spring seat past groove to install stopper ring Stopper ring will lock into groove when installed correctly 23 See Figure 2 94 Install slider tube cap 24 See Figure 2 95 Install fork assemblies through upper and lower triple clamps Figure 2 91 Install New Dust Seal Figure 2 92 Remove Slider Tube...

Page 132: ... of fork is not below top surface of upper triple clamp b Tighten upper triple clamp pinch screws at sliders to 13 16 ft lbs 18 22 Nm c Tighten lower triple clamp pinch screws to 22 29 ft lbs 30 39 Nm d See Figure 2 98 Tighten headlamp brackets flush against bottom of top triple clamp 4 Install front fender See 2 23 FENDERS 5 Install front wheel See 2 5 FRONT WHEEL 6 Install front brake caliper Se...

Page 133: ...wer triple clamp 8 and remove upper triple clamp 3 9 Remove upper dust shield 5 and upper bearing 6 10 Lower triple clamp can be removed 11 Remove lower bearing 6 and lower dust shield 5 from lower triple clamp CLEANING AND INSPECTION 1 See Figure 2 99 Clean the dust shields 5 bearing cups 7 fork stem and lower triple clamp 8 and frame with solvent 2 Carefully inspect bearing races and assemblies ...

Page 134: ...4 Insert lower triple clamp 8 through the steering head Install the upper bearing 6 with small end down and dust shield 5 onto fork stem 5 Apply LOCTITE 243 Blue to fork stem Loosely install upper triple clamp 3 using cap nut 1 6 Install fork assemblies See 2 17 FRONT FORK 7 Tighten cap nut 1 until the bearings have no free play Make sure the fork stem turns freely 8 Check steering head bearing ad...

Page 135: ...arm bolt 6 and install Tighten to 24 26 ft lbs 33 35 Nm 3 Apply LOCTITE 243 BLUE to pinch screw 1 and install Tighten to 17 19 ft lbs 23 26 Nm 4 Install well nuts 5 Install rear shock and fastener Tighten to 35 40 ft lbs 47 54 Nm 6 Install rear wheel axle brakes and spacers Tighten rear axle nut to 48 52 ft lbs 65 71 Nm 7 Install drive belt 8 Install rear fender lower belt guard and sprocket cover...

Page 136: ... Retaining ring may crack if not oriented as stated in step 3 4 Install new exhaust port gasket 1 5 Position muffler on motor Hand tighten nuts 13 6 Slide muffler over bushings on front mount 7 Hand thread bolt washer and nut to front muffler support 8 Install rear muffler strap 15 NOTE A rubber mallet may be used to tap the muffler strap into muf fler notches 9 Install right side muffler spacers ...

Page 137: ...ort 2 Retaining ring exhaust 3 Clamp exhaust ring 4 Bolt 5 Screw 6 Screw 7 Washer 6 8 Spacer 9 Spacer right 10 Spacer left 11 Spacer 12 Nut 2 13 Nut 2 14 Muffler complete 15 Muffler strap rear 16 Bracket 2 17 Grommet 2 4 12 7 6 12 3 2 14 7 8 15 13 1 17 11 10 16 9 16 7 17 7 5 7 7 a0160x2x ...

Page 138: ...See Figure 2 103 On left side install clamp with oil tank drain hose and breather hose 4 On right side install rear master cylinder spacers reser voir and brake pedal See 2 13 REAR BRAKE MASTER CYLINDER 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 causing loss of control of vehi cl...

Page 139: ...ION 1 Apply LOCTITE 243 Blue to threads of three screws 2 Position sprocket cover and install three screws and washers Tighten fasteners to 30 36 in lbs 3 4 Nm 3 Move pedal assembly in position and install pedal bolt Tighten pedal bolt to 72 96 in lbs 8 11 Nm 4 Install master cylinder bolts and spacers See 2 13 REAR BRAKE MASTER CYLINDER Figure 2 104 Master Cylinder Mounting Figure 2 105 Sprocket ...

Page 140: ...el off floor 2 Align front fender mounting holes with front fork bracket NOTE The longer end of the fender faces away from the front end 3 Apply LOCTITE 243 Blue to first few threads of four fender mounting screws 4 See Figure 2 106 Install front fender with four fender mounting screws 5 Tighten fender mounting screws to 27 30 in lbs 3 1 3 4 Nm Figure 2 106 Front Fender Assembly Mounting Screws Fi...

Page 141: ...s on rear fender 3 Tighten rear fender mounting screws to 30 36 in lbs 3 4 Nm 4 Install right side footrest support bracket See 2 21 FOOTPEGS AND FOOTPEG SUPPORT BRACKETS 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 causing loss of control of vehi cle and death or serious injury 5 ...

Page 142: ...wash ers securing lower belt guard to swingarm 2 Remove belt guard INSTALLATION 1 Position belt guard over tabs on swingarm 2 Secure belt guard with two screws and nylon washers 3 Tighten screws to 30 36 in lbs 3 4 Nm Figure 2 109 Lower Belt Guard a0132x2x 1 Lower belt guard 2 Screws 2 3 Nylon washers 2 1 2 3 ...

Page 143: ...gative cable 6 Unplug taillight 7 Cut cable strap holding taillight and turn signal wires 8 Unplug turn signals 9 Remove nut 8 and lock washer 7 10 Remove turn signals 6 11 Remove nuts and flat washers from back of taillight 12 Remove taillight 13 Remove bolts 4 and nuts 9 14 Remove license plate bracket 5 Figure 2 110 Tail Section 1 7 16 17 2 3 4 5 6 8 9 10 11 12 20 18 19 15 14 a0146a2x 1 Tail se...

Page 144: ...nnect rear wire harness and mount on T stud INSTALLATION TAIL SECTION 1 See Figure 2 110 Install license plate bracket 5 using fasteners 4 and nuts 9 in rear holes 2 Install taillight using flat washers and nuts 3 Install turn signals 6 using lock washers 7 and nuts 8 4 Connect turn signal wires and taillight wires Cable tie together 5 Install tail section 1 using fasteners 3 19 20 6 Connect batte...

Page 145: ...indscreen trim 4 Remove windscreen mounting brackets if required See 7 17 HEADLAMP INSTALLATION 1 If removed install both windscreen brackets See 7 17 HEADLAMP 2 Verify trim is installed on windscreen 3 See Figure 2 111 Install two screws and nylon washers on each side Tighten screws to 9 11 in lbs 1 1 2 Nm Figure 2 111 Remove Screws Figure 2 112 Windscreen Trim 3779 3797 ...

Page 146: ...To remove speedometer see 7 25 ELECTRONIC SPEED OMETER INSTALLATION 1 See Figure 2 113 Install odometer reset switch to instru ment panel and install rubber boot 2 Install connector 39 on back of speedometer 3 Apply LOCTITE 243 Blue to threads of mounting screws Install dash with two mounting screws Tighten screws to 30 36 in lbs 3 4 Nm Figure 2 113 Instrument Panel a0154x2x 1 Screws 2 2 Odometer ...

Page 147: ...seat with one hand and grasp the front section of the seat with the other hand 3 See Figure 2 117 Push seat forward while flexing the rear section of the seat upward until the tongue locks into the bracket located on the frame 4 Push down firmly on the seat NOTE You will hear a click when the locating tab and seat latch lock together correctly 11WARNING 1WARNING After installing seat pull upward o...

Page 148: ... of the starter interlock system INSPECTION 1 Test the sidestand with the vehicle upright and level The sidestand should move freely into extended down and up position 2 Check sidestand switch operation after first 1000 miles 1600 km and every 2500 miles 4000 km DISASSEMBLY REMOVAL 1 Raise rear wheel off floor using REAR WHEEL SUP PORT STAND Part No B 41174 2 Disconnect electrical connection 3 Cut...

Page 149: ...d upper handlebar clamps Final tighten to 120 144 in lbs 14 16 Nm 4 Install master cylinder Tighten master cylinder clamp bolts to 80 120 in lbs 9 14 Nm 5 Install throttle grip 6 Hook ferules to cable wheel Position cables in notches of switch housing 14 7 Position housings on right handlebar Front housing has locating pin that must align with hole in handlebar Install fasteners longer screw on bo...

Page 150: ...lation 1 See Figure 2 121 Position new isolator in frame 2 Install two outboard isolator bolts 1 Tighten 30 33 ft lbs 41 45 Nm 3 Install main isolator bolt and new nut 2 Tighten main isolator bolt to 63 70 ft lbs 85 95 Nm 4 Tighten front ground strap bolt to 30 33 ft lbs 41 45 Nm 5 Install clutch cable to clip 6 Install horn cable strap 7 Install fuel tank See 4 2 FUEL TANK COVER FUEL TANK 11WARNI...

Page 151: ...e or lower motorcycle to remove isolator Installation 1 See Figure 2 123 Clean engine bolt holes and bolts Do not re tap holes 2 Apply LOCTITE 243 Blue to bolts and install four isola tor to engine bolts Tighten bolts to 23 27 ft lbs 31 2 36 6 Nm 3 See Figure 2 122 Apply LOCTITE 272 Red to the two frame to isolator bolts Tighten bolts to 30 33 ft lbs 41 45 Nm 4 Install rear shock absorber See 2 15...

Page 152: ...2004 Buell P3 Chassis 2 73 HOME Figure 2 122 Frame to Isolator Bolts Figure 2 123 Rear Engine Mount Isolator 7745 7743 2 1 1 Rear isolator 2 Bolts 4 ...

Page 153: ...6 Cylinder And Piston 3 40 3 7 Lubrication System 3 51 3 8 Oil Reservoir and Oil Hose Routing 3 52 3 9 Oil Pressure Indicator Switch 3 54 3 10 Crankcase Breathing System 3 55 3 11 Oiling System 3 56 3 12 Oil Pump 3 57 3 13 Oil Filter Mount 3 60 3 14 Hydraulic Lifters 3 61 3 15 Gearcase Cover and Cam Gears 3 63 3 16 Crankcase 3 73 ENGINE 3 Table Of Contents ...

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Page 155: ......

Page 156: ... 1 BTDC Timing Advance at 1200 RPM 20 BTDC Regular Idle 1200 RPM Fast Idle 2000 RPM Table 3 3 Valve and Valve Seat Specifications VALVE NEW COMPONENTS SERVICE WEAR LIMITS inches mm inches mm Fit in guide Exhaust 0 0015 0 0033 0 0381 0 0838 0 0040 0 1016 Intake 0 0008 0 0026 0 0200 0 0700 0 0035 0 0889 Seat width 0 040 0 062 1 016 1 575 0 090 2 286 Stem protrusion from cylinder valve pocket 1 975 2...

Page 157: ... shaft fit in rocker cover loose 0 0007 0 0022 0 018 0 056 0 0035 0 0889 Table 3 7 Piston Specifications PISTON NEW COMPONENTS SERVICE WEAR LIMITS inches mm inches mm Compression ring gap top and 2nd 0 007 0 020 0 178 0 508 0 032 0 813 Oil control ring rail gap 0 009 0 052 0 229 1 321 0 065 1 651 Compression ring side clearance Top 0 0020 0 0045 0 0508 0 1143 0 0065 0 1651 2nd 0 0016 0 0041 0 0410...

Page 158: ...5 0 00175 0 03175 0 04445 0 00200 0 05080 Side play between flywheels 0 005 0 025 0 127 0 635 0 030 0 762 Fit on crankpin loose 0 0004 0 0017 0 0102 0 0432 0 0027 0 0686 Connecting rod race ID 1 6245 1 6250 41 2623 41 2750 1 6270 41 3258 Table 3 11 Hydraulic Lifter Specifications HYDRAULIC LIFTER NEW COMPONENTS SERVICE WEAR LIMITS inches mm inches mm Fit in guide 0 0008 0 0020 0 0203 0 0508 0 0030...

Page 159: ...51 0 002 0 051 End play 0 001 0 005 0 025 0 127 0 005 0 127 Table 3 15 Sprocket Shaft Bearing Specifications SPROCKET SHAFT BEARING NEW COMPONENTS SERVICE WEAR LIMITS inches mm inches mm Outer race fit in crankcase tight 0 0004 0 0024 0 0102 0 0610 Bearing inner race fit on shaft tight 0 0002 0 0015 0 0051 0 0381 Table 3 16 Pinion Shaft Bearing Specifications PINION SHAFT BEARINGS NEW COMPONENTS S...

Page 160: ...s 5 8 Nm LOCTITE 243 blue Page 3 20 Oil filter adapter 96 144 in lbs 11 16 Nm LOCTITE 243 blue Page 3 60 Oil pressure signal light switch 50 70 in lbs 6 8 Nm Page 3 60 Oil pump cover screws 70 80 in lbs 8 9 Nm TORX page 3 59 Oil pump mounting screws 125 150 in lbs 14 17 Nm Page 3 59 Pinion shaft nut 19 21 ft lbs 26 29 Nm Page 3 71 Piston jet TORX screws 25 35 in lbs 2 8 4 Nm Loctite 222 page 3 82 ...

Page 161: ...shings and main bearings are lubricated by oil spray thrown off connecting rods and crankshaft and by oil draining from each rocker box through an internal drain passage in each cylinder and each tappet guide Oil is transferred to the teeth of all the cam gears by way of the gear meshing action The oil scavenging section of the pump returns oil to the tank from the engine See 3 7 LUBRICATION SYSTE...

Page 162: ...round spark plug and remove spark plug 3 Remove air cleaner and set carburetor throttle in wide open position 4 Remove timing inspection plug from crankcase 5 The piston in cylinder being tested must be at top dead center of compression stroke during test 6 To keep engine from turning over when air pressure is applied to cylinder engage transmission in fifth gear and lock the rear brake 7 Followin...

Page 163: ...to lower motor 7 Remove horn See 7 22 HORN 8 See Figure 3 1 Remove crankcase breather hose and crankcase breather from rocker box grommet CAUTION See Figure 3 2 Do not attempt to remove isolator mount from cylinder head Isolator mount is an integral compo nent and is not meant to be removed unless absolutely necessary Repeated removals and installations will damage cylinder head threads NOTES Remo...

Page 164: ...ar tie bar at frame NOTE Remove entire air cleaner and carburetor as an assembly 14 See Figure 3 5 Remove screws 4 on both air cleaner brackets 2 3 Figure 3 3 Front Isolator Mount Figure 3 4 Remove Top Rear Tie Bar 1 Frame 2 Locknut 3 Snubber 4 Bolt 5 Spacer 6 Front isolator 7 Standoff 1 a0162x6x 2 3 4 5 6 7 7627 Figure 3 5 Air Cleaner Assembly 1 Air cleaner screw 2 Air cleaner bracket left front ...

Page 165: ...plete disassembly preparation for top end servicing You may now proceed with TOP END DISASSEMLY PROCEDURES See 3 5 CYLINDER HEAD If continuing engine removal proceed to step 20 NOTE The remaining steps are required to complete engine removal 19 Place jack under the motor Use jack to lower motor 20 Move jack forward 21 Place wooden cradle under engine Figure 3 6 Hose Clamp Figure 3 7 Crankcase Brea...

Page 166: ...ove right side rider footpeg bracket assembly See 2 21 FOOTPEGS AND FOOTPEG SUP PORT BRACKETS 26 Introduce freeplay and remove clutch cable at hand lever location See 1 10 CLUTCH Figure 3 9 Rear Master Cylinder and Brake Line Assembly 1 Screw 2 Brake fluid reservoir 3 Screw 4 Brake line bracket 5 Brake line 6 Screw 7 Master cylinder 8 Spacer 1 3 6 7 8 2 5 4 a0017x3x Figure 3 10 Footpeg Bracket Ass...

Page 167: ...seat right side tucked in under cavity Sidestand switch 60 Tie wrapped to rear brake line Neutral switch 131 Disconnect at neutral switch Oil pressure switch 120 Disconnect at oil pressure switch Alternator stator 46 Located under seat left side Starter solenoid wire 128 Disconnect at starter Spark plug wire Located on spark plug Battery positive wire Disconnect at main circuit breaker Rear brake ...

Page 168: ...RBER 30 See Figure 3 12 Loosen nut on hose routing clamp 31 See Figure 3 13 Disconnect feed return transmission and crankcase vent lines 32 See Figure 3 14 Remove rear motor mount bolts Figure 3 11 Hoisting Bike Figure 3 12 Loosen Clamp 7650 7718 Figure 3 13 Disconnect Lines Figure 3 14 Removing Rear Motor Mount Bolts 7634 1 Oil return 2 Transmission vent 3 Crankcase vent 4 Oil feed 4 2 1 3 7623 ...

Page 169: ...ee Figure 3 15 Lift chassis and roll away from engine 34 See Figure 3 16 Remove air cleaner box bracket 35 See Figure 3 17 Remove rear engine mount 36 See Figure 3 18 Loosen swingarm pinch bolt Figure 3 15 Move Chassis From Engine Figure 3 16 Air Cleaner Bracket 7651 7652 Figure 3 17 Rear Engine Mount Figure 3 18 Swingarm Pivot Shaft Pinch Bolt 7653 7654 ...

Page 170: ... Figure 3 19 Remove swingarm pivot shaft and rear wheel as an assembly See 2 19 SWINGARM 38 See Figure 3 20 Remove sidestand and bracket assem bly See 2 29 SIDESTAND Figure 3 19 Swingarm Pivot Shaft 7655 Figure 3 20 Sidestand Bracket 7656 ...

Page 171: ...Install swingarm pivot shaft and rear wheel as an assembly and tighten pivot shaft to 24 26 ft lbs 32 35 Nm See 2 19 SWINGARM 5 See Figure 3 23 Install swingarm pinch bolt a Apply several drops of LOCTITE 243 blue to last few threads b Tighten to17 19 ft lbs 23 26 Nm 6 See Figure 3 24 Install rear engine mount a Apply several drops of LOCTITE 243 blue to last few threads b Tighten to 23 27 ft lbs ...

Page 172: ... and raise hoist until straps tighten 10 Place jack under the motor Use jack to raise motor 11 Move jack backward 12 See Figure 3 28 Install rear motor mount bolts a Apply several drops of LOCTITE 262 red to last few threads b Tighten to 30 33 ft lbs 41 45 Nm Figure 3 25 Bracket Left Side Air Cleaner Figure 3 26 Move Chassis to Engine 7652 7651 Figure 3 27 Hoisting Bike Figure 3 28 Installing Rear...

Page 173: ...Tighten hose clamps using Hose Clamp Pliers Part No HD 41137 15 See Figure 3 31 Tighten nut on hose routing clamp 16 Install rear shock See 2 15 REAR SHOCK ABSORBER Figure 3 29 Connect Lines Figure 3 30 Tighten Hose Clamps 7634 1 Oil return 2 Transmission vent 3 Crankcase vent 4 Feed 4 2 1 3 7635 Figure 3 31 Tighten Clamp 7718 ...

Page 174: ... side tucked in under cavity Sidestand switch 60 Tie wrapped to rear brake line Neutral switch 131 Disconnect at neutral switch Oil pressure switch 120 Disconnect at oil pressure switch Alternator stator 46 Located under seat left side Starter solenoid wire 128 Disconnect at starter Spark plug wire Located on spark plug Battery positive wire Disconnect at main circuit breaker Rear brake light swit...

Page 175: ...43 blue to last few threads b Tighten to 48 72 in lbs 5 8 Nm 22 See Figure 3 33 Install right side rider footpeg bracket assembly See 2 21 FOOTPEGS AND FOOTPEG SUP PORT BRACKETS Figure 3 32 Rear Master Cylinder and Brake Line Assembly 1 Screw 2 Brake fluid reservoir 3 Screw 4 Brake line bracket 5 Screw 6 Brake line 7 Master cylinder 8 Spacer 1 3 6 7 8 5 4 a0017x3x 2 Figure 3 33 Footpeg Bracket Ass...

Page 176: ... and tighten screws on both air cleaner brackets a Right bracket to air cleaner 36 60 in lbs 4 1 6 8 Nm b Left bracket to crankcases 120 144 in lbs 13 6 16 3 Nm c Install screw on air cleaner cover Figure 3 34 Auto Enrichener Plug Figure 3 35 Crankcase Breather Hose 1 Auto enrichener plug 2 Frame 2 1 7631 7649 1 Breather hose 2 Three way connector 1 2 Figure 3 36 Hose Clamp Figure 3 37 Air Cleaner...

Page 177: ...l the two mounted cylinder head bolts from the front isolator engine bracket marked DO NOT REMOVE a Apply several drops of LOCTITE 262 red to last few threads of new bolts b Apply a thin film of clean HD 20W50 engine oil to both sides of new thick washers and to bottom of bolt heads Exercise caution to avoid mixing oil on washers with LOCTITE on bolts c Tighten bolts to 60 ft lbs 81 3 Nm initially...

Page 178: ...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 41 Connect both battery cables positive cable first See 7 16 BATTERY 11WARNING 1WARNING Pull up on seat to verify that it is properly secured front and rear A loose seat may shift during vehicle operation and sta...

Page 179: ... Gasket 4 6 Rocker cover top 7 Bolt 3 8 Washer 3 9 Gasket inner 10 Gasket lower 11 Rocker arm shafts 12 Bolt 2 13 washer 2 14 Rocker cover lower 15 Rocker arm 2 16 Bushing rocker arm 4 17 Gasket lower rocker cover 18 Hydraulic lifter 19 Screw tappet anti rotation 2 20 Gasket push rod cover 21 Push rod cover 22 Screw 4 23 O ring push rod cover 2 24 Push rod 25 Washer 4 26 Bolt 4 2 3 4 5 7 8 11 12 1...

Page 180: ...oosen the four rocker arm fasteners 3 in 1 4 1 2 turn increments using a cross pattern in order to relieve valve spring pressure on the lower rocker box 7 See Figure 3 44 Remove lower rocker cover NOTE Remove lower rocker box as an assembly then disassemble as required CAUTION Mark rocker arm shafts for reassembly in their original positions Valve train components must be reinstalled in their orig...

Page 181: ...over gasket and valve tappets DISASSEMBLY 1 See Figure 3 48 Clamp VALVE SPRING COMPRES SOR TOOL Part No HD 34736B in vise 2 Compress valve springs with VALVE SPRING COM PRESSOR 3 See Figure 3 49 Remove valve keepers upper collar and valve springs Mark valve keepers for reassembly in their original locations 4 Use a fine tooth file to remove any burrs on the valve stem at the keeper groove 5 Mark v...

Page 182: ...ring 6 Outer valve spring 7 Valve seal 8 Lower valve spring collar 9 Valve guide intake exhaust 2 10 Cylinder head 11 Exhaust port stud 12 Cylinder head gasket 13 Cylinder o ring 4 14 Cylinder insert 15 Cylinder w piston rings 16 Cylinder base gasket 17 Cylinder base stud 18 Exhaust valve 19 Exhaust valve seat 1 2 a0021x3x 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 15 16 17 ...

Page 183: ...rbon or dirt with compressed air 2 Soak cylinder head in an aluminum compatible cleaner solvent to loosen carbon deposits 3 Wash all parts in non flammable solvent followed by a thorough washing with hot soapy water Blow out oil passages in head Be sure they are free of sludge and carbon particles Remove loosened carbon from valve head and stem using a wire wheel Never use a file or other hardened...

Page 184: ...gure 3 54 Measure rocker arm bushing inner diameter 4 Check the measurements obtained in Steps 2 3 against the SERVICE WEAR LIMITS Repair or replace parts exceeding limits 5 Assemble rocker arms and rocker arm shafts into lower rocker cover 6 Check end play of rocker arm with feeler gauge 7 Replace rocker arm or lower cover or both if end play exceeds 0 025 in 0 635 mm Figure 3 51 Measuring Rocker...

Page 185: ...movement will prevent the proper transfer of heat from the valve The seat surface must be flush with or below the head surface See 3 1 SPECIFICATIONS for valve seat to cylinder head fit Valve Guides 1 Clean valve guides by lightly honing with VALVE GUIDE HONE Part No HD 34723 2 Scrub guides with VALVE GUIDE BRUSH Part No HD 34751 and hot soapy water Measure valve stem outer diameter and valve guid...

Page 186: ...From opposite side of rocker arm press out bushing and tap using a discarded rocker arm shaft 2 Press replacement bushing into rocker arm flush with arm end and split portion of bushing towards top of arm 3 Using remaining old bushing as a pilot line ream new bushing with ROCKER ARM BUSHING REAMER Part No HD 94804 57 4 Repeat for other end of rocker arm Figure 3 57 Replacing Rocker Arm Bushings 87...

Page 187: ...e guide At this point 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 NOTE The hone is not intended to remove material 6 Apply the proper surface ...

Page 188: ... cut and be sure to highlight all 3 angles Allow marker to dry before proceeding NOTES Always ensure cutter blades and cutter pilot are clean before beginning the cutting process The correct clean ing brush is supplied with the Neway tool set Also ensure the inside of the valve guide is clean by using Kent Moore cleaning brush Part No HD 34751 6 Choose the cutter pilot that fits properly into the ...

Page 189: ...plete clean up of the 46 angle and the width is at least 062 in 1 575 mm pro ceed to the next step 12 Select the proper 60 cutter and gently slide the cutter down the cutter pilot to the valve seat 13 Remove just enough material to provide an even valve seat width of 040 062 in 1 016 1 575 mm 14 Remove cutter pilot and wash head thoroughly and dry completely 15 Repeat the process on any valve seat...

Page 190: ...r groove when installing valve stem seal If the seal is installed without using the protective sleeve the seal will be damaged CAUTION Do not remove valve after seal is installed Otherwise sharp edges on keeper groove will damage seal 7 See Figure 3 63 Tap the valve stem seal onto the valve guide using the VALVE SEAL INSTALLATION TOOL Part No HD 34643A and DRIVER HANDLE Part No HD 34740 The seal i...

Page 191: ...3 23 Identify push rod color coding length and respective push rod positions in engine Place intake and exhaust push rods onto seat at top of tappet CAUTION After head has been installed do not turn engine over until both push rods can be turned with fingers Other wise damage to push rods or rocker arms may result Figure 3 64 Push Rod Location Table 3 23 Push Rod Selection POSITION COLOR CODES LEN...

Page 192: ...xcess oil CAUTION The procedure for tightening the head screws is critical to proper distribution of pressure over gasket area It prevents gasket leaks stud failure and head and cylin der distortion 6 Start the cylinder head screws onto the cylinder studs two short bolts on the left side of the engine two long bolts on the right 7 See Figure 3 66 Always start with screw numbered one as shown In in...

Page 193: ...er 10 Gasket lower 11 Rocker arm shafts 12 Bolt 2 13 washer 2 14 Rocker cover lower 15 Rocker arm 2 16 Bushing rocker arm 4 17 Gasket lower rocker cover 18 Hydraulic lifter 2 19 Screw tappet anti rotation 2 20 Gasket push rod cover 21 Push rod cover 22 Screw 4 23 O ring push rod cover 2 24 Push rod 25 Washer 4 26 Bolt 4 1 4 12 15 17 21 20 25 10 b0960x3x 18 2 3 5 6 7 8 9 13 14 16 11 26 24 23 22 19 ...

Page 194: ...sequences sizes and torque specifications are listed in Table 3 24 a Tighten bolts 1 to 18 22 ft lbs 24 30 Nm b Tighten bolts 2 to 135 155 in lbs 15 18 Nm c Tighten bolts 3 to 135 155 in lbs 15 18 Nm 11 See Figure 3 68 Install upper rocker covers a Place a new inner gasket on lower rocker box assembly b Place a new lower gasket on lower rocker cover c Install upper rocker cover using screws with w...

Page 195: ...be careful not to bend the cylin der studs The slightest bend could cause a stress riser and lead to stud failure 7 Install a 6 0 in 152 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the piston 11WARNING 1WARNING Retaining rings are highly compressed in the ring groove and may fly out with considerable force when pried out Always wear...

Page 196: ...remove both piston pin circlips during piston removal Leave the second circlip in the pin bore 9 See Figure 3 72 The arrow at the top of pistons must always point toward the front of the engine CAUTION Handle the piston with extreme care The alloy used in these pistons is very hard Any scratches gouges or other marks in the piston could score the cylinder during engine operation and cause engine d...

Page 197: ...n to bushing clearance exceeds 0 00200 in 0 05080 mm replace worn parts 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 should be refitted This requires removing and disassembling engine crankcase Checking Gasket Surface CAU...

Page 198: ...so show any cylinder taper or bulge 5 See Table 3 25 If cylinder is not scuffed or scored and is within service limit see next section FITTING PISTON RINGS NOTE If piston clearance exceeds service wear limit cylinders should be re bored and or honed to next standard oversize and refitted with the corresponding piston and rings Do not fit piston tighter than 0 0007 in 0 0178 mm See 3 1 SPECIFI CATI...

Page 199: ...ng wear and possible engine failure 3 Thoroughly wash the cylinder bore with liquid dishwash ing soap and warm water to remove all abrasive particles and residual grit Continue cleaning until a clean cloth shows no evidence or dirt or debris 11WARNING 1WARNING Low pressure compressed air can blow debris into your face and eyes Always wear eye protection or a face shield when using pressurized air ...

Page 200: ...n and mea sure the ring end gap with a feeler gauge Do not use the ring if the end gap does not fall within the following spec ifications See Table 3 27 NOTE Ring end gap dimensions also apply to oversize rings Replace ring if end gap exceeds specification If end gap is under specification filing is permissible Figure 3 75 Piston Rings 1 Top compression ring install either side up 2 Second compres...

Page 201: ... surface when installing rings NOTE Install second compression ring with dot towards top 3 See Figure 3 78 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 79 Check for proper side clearance with thickness gauge as shown See 3 1 SPECIFICATIONS NOTE If the ring grooves are clean and the side play is ...

Page 202: ...ion as it was for removal of the bushing 7 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 8 Hone bushing to final size using WRIST PIN BUSHING HONE Part No HD 35102 Use a liberal amount of honing oil to prevent damage t...

Page 203: ...if it has been installed and then removed for any reason A loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair 4 See Figure 3 86 Install new piston pin retaining rings 1 using PISTON PIN RETAINING RING INSTALLER 2 Part No HD 34623B Place new retaining ring on tool with gap pointing up See Figure 3 85 NOTE Make sure the ring groove is clean Ring mu...

Page 204: ... Remove protective sleeves from cylinder studs Install a new cylinder base gasket Make sure the piston does not bump the studs or crankcase 10 Install cylinder over piston 11 Remove PISTON RING COMPRESSOR 12 Assemble cylinder head See 3 5 CYLINDER HEAD 13 Install cylinder head See 3 5 CYLINDER HEAD 14 Install assembled engine See 3 4 ENGINE INSTALLA TION Figure 3 87 Ring End Gap Position Figure 3 ...

Page 205: ...3 50 2004 Buell P3 Engine HOME NOTES ...

Page 206: ...combustion in a gasoline engine produces water vapor and carbon dioxide 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 bre...

Page 207: ...m left side of the oil reservoir supplies the feed hose and the oil drain hose After diverging from the feed and return hoses the vent hose continues on to the right side of the motorcycle Here the vent hose connects to an elbow fitting on the gearcase cover Figure 3 90 Oil Reservoir and Hose Routing 1 Frame backbone 2 Drain plug 3 3 8 Spring clamp 4 Hose oil drain 5 Hose oil return line 6 1 4 Spr...

Page 208: ...itting the return hose connects forward and above See Figure 3 92 The drain hose attaches to the left side of the footpeg support bracket frame Figure 3 91 Oil Pump Connections 1 Oil feed line into pump 2 Oil pump 3 Oil feed line out to oil filter 4 Oil return line 5 Oil filter 6 Oil pressure indicator switch 3 1 2 4 5 6 Figure 3 92 Oil Drain Hose 1 Breather hose 2 Oil drain hose 1 2 ...

Page 209: ...e more viscous i e thicker 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 OIL PRESSURE GAUGE Part No HD 96921 52B and OIL PRESSURE GAUGE ADAPTER Part No HD 96940 58 Remove oil press...

Page 210: ...PCV located on top of the rocker box cover From the PCV the air enters the crankcase breather hose The crankcase breather hose splits with one hose crankcase breather hose going to the air cleaner and the other hose crankcase breather drain hose going to the footrest support bracket Crankcase air is routed to the air cleaner box where it is directed into the carburetor s venturi Any residual oil d...

Page 211: ...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 shafts and bushings ...

Page 212: ...ck into the pump and is forced by the gerotor scavenge set back to the oil reservoir The oil pump seldom needs servicing Before you disassem ble an oil pump suspected of not producing adequate oil pres sure be sure that all possible related malfunctions have been eliminated 1 Make sure all oil hose clamps are tight and that hoses are not pinched or damaged 2 Check level and condition of oil in tan...

Page 213: ...ure compressed air can blow debris into your face and eyes Always wear eye protection or a face shield when using pressurized air Failure to take adequate safety precautions could result in death or serious injury 1 Clean all parts in cleaning solvent Blow out holes and oil passages with compressed air 2 See Figure 3 97 Inspect both gerotor sets for wear a Mesh pieces of each set together as shown...

Page 214: ...in pump body 6 See Figure 3 95 Place gerotor feed set over gear shaft 7 Place cover onto pump body Install cover TORX screws Tighten to 70 80 in lbs 8 9 Nm 8 Place new mounting gasket in position NOTE Use new hose clamps If fittings were removed use TEFLON PIPE SEALANT or HYLOMAR on fitting threads 9 See Figure 3 96 Attach return hose connection 10 Secure pump to crankcase with mounting screws Tig...

Page 215: ...ry Thoroughly clean all parts in cleaning solvent Blow out holes and passages using compressed air ASSEMBLY NOTE Use TEFLON PIPE SEALANT or HYLOMAR on all fittings installed to oil filter mount 1 See Figure 3 99 Install oil pressure indicator switch using 1 OIL PRESSURE SENDING UNIT WRENCH Part No HD 41675 Tighten to 50 70 in lbs 6 8 Nm 2 Attach indicator lamp wire 2 to oil pressure indicator swit...

Page 216: ...sh rod cover a Remove screws b Remove push rod cover c Remove gasket and o rings Discard parts 5 Remove both valve hydraulic lifters a Remove anti rotation screws b Remove lifters from crankcase bore using a thin bladed screwdriver Mark the location and orienta tion front back of each lifter CLEANING AND INSPECTION 11WARNING 1WARNING Low pressure compressed air can blow debris into your face and e...

Page 217: ...rs in the holes in lifter block b Tighten anti rotation screws to 55 65 in lbs 6 7 Nm 5 Install push rod cover a Slide new gasket cover over bottom of push rod cover b Position push rod cover onto crankcase c Install screws through holes in push rod cover into tapped holes in crankcase Tighten screws evenly to 30 40 in lbs 3 5 Nm d Place new o rings on top of push rod cover 6 Install push rods cyl...

Page 218: ...tant to know and understand all inspection procedures and how components interact Figure 3 103 Gearcase Cover Cam Assembly a0030x3x 1 Crankcase half 2 Dowel pin 3 Inner camshaft gear bushing 4 W cam gear set 5 Oil pump drive gear 6 W cam pinion and drive gear set 7 Nut 8 Gear shaft pinion bushing 9 Cam gear shaft outer bushing 10 Key 11 Gearcase cover gasket 12 Gearcase cover 13 Seal 14 Sems screw...

Page 219: ...ff pinion shaft CLEANING AND INSPECTION 1 Thoroughly clean gearcase compartment gearcase cover and gears in solvent to remove oil and carbon deposits 11WARNING 1WARNING Low pressure compressed air can blow debris into your face and eyes Always wear eye protection or a face shield when using pressurized air Failure to take ade quate safety precautions could result in death or serious injury 2 Blow ...

Page 220: ...e of the keyway This dot identi fies the pinion shaft inner race size Do not use this dot to select pinion gear size See Table 3 29 Compare the previously measured diameter of each gear with the specifications listed in inches shown in the table to determine amount of wear on gear teeth NOTE Prior to changing any cam gears check gear shaft fit within corresponding bushings Worn bushings can cause ...

Page 221: ...h two screws c Apply several drops of LOCTITE 262 red to last few threads of nut d Install nut to pinion shaft Tighten nut to 19 21 ft lbs 26 29 Nm plus an additional 15 to 17 rotation 3 See Figure 3 103 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 NOTE Because of the ...

Page 222: ...lat blade screwdriver c Measure 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 14 HYDRAULIC LIFTERS 8 Install cam position sensor and roto...

Page 223: ...ith indicator stem on end of gearshaft 4 To obtain an accurate flywheel end play reading preload sprocket shaft bearings Create a suitable tool by welding 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...

Page 224: ...3 15 GEARCASE COVER AND CAM GEARS 5 Remove primary cover and primary drive clutch compo nents See 6 2 PRIMARY CHAIN 6 Remove starter motor See 5 7 STARTER 7 See Figure 3 112 Remove screws and rear engine mount bolts securing crankcase halves together 8 Tap crankcase with plastic mallet to loosen and separate the halves Figure 3 112 Crankcase Hardware 1 Screw 4 2 Washer 4 3 Rear isolator 4 Dowel pi...

Page 225: ...ot drive flywheel assembly from crank case half as flywheels may be knocked out of alignment NOTE See Figure 3 114 If it is necessary to remove either the pin ion shaft bearing or sprocket shaft bearing proceed as fol lows 10 Gearshaft bearing will remain on flywheel pinion shaft Remove retaining ring and bearing may be slipped off pinion shaft Figure 3 113 Pressing On End Of Sprocket Shaft To Rem...

Page 226: ...0008 in 0 0051 0 0203 mm is established during crankcase set or flywheel assembly replacement and engine rebuild 14 See Figure 3 118 Installed inner races are identified at the factory as shown 15 See Table 3 33 Outer races are identified at the factory as shown NOTE The different sizes of crankcase sets and flywheel assemblies will not have separate part numbers That is a replacement crankcase se...

Page 227: ...49 31 7500 mm A White 1 2496 1 2498 in 31 7398 31 7449 mm B Green SERVICE WEAR LIMIT 1 2492 in 31 7297 mm a0131x3x Inner Race Paint Dot Location Figure 3 119 Factory Outer Race Sizes See Table 3 33 for Identification RACE ID CLASS NO STAMPED IDENTIFICATION 1 5646 1 5648 in 39 7408 39 7459 mm 1 1 1 5648 1 5650 in 39 7459 39 7510 mm 2 2 1 5650 1 5652 in 39 7510 39 7561 mm 3 3 SERVICE WEAR LIMIT 1 56...

Page 228: ... 1 5672 in 39 8069 mm go to Step 5 b If roundness or taper do not meet specifications continue lapping until specifications are met c If all specifications are met continue at Step 7 to remove and size inner race 5 Press the outer race from the right crankcase Press new outer race into crankcase flush with inside edge of cast in insert See Figure 3 121 Dimensions are shown for fabrication of tools...

Page 229: ...he smallest outer race ID measurement is 1 5651 in 39 754 mm This requires an inner race OD range of 1 2496 1 2504 in 31 740 31 760 mm b Grind inner race Measure OD at four places Check that specifications in Step 8 are met c For example purposes suppose the largest inner race OD measurement after grinding is 1 2499 in 31 747 mm OD d With a 1 5651 in 39 754 mm ID outer race and a 1 2499 in 31 747 ...

Page 230: ...lue 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 ...

Page 231: ...shing or bushing will bell a condition 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...

Page 232: ...g distorted pinched or otherwise damaged will result in either oil leakage or low oil pres sure NOTE Gasket is part of the piston jet assembly Gasket not sold sep arately 1 Install new piston oil jet assembly in right crankcase 2 Apply Loctite 222 purple to threads of TORX screws 3 With the jet pointed upward install TORX screws to secure piston jet to crankcase Tighten screws to 25 35 in lbs 2 8 ...

Page 233: ...of the snap ring at the 10 and 2 o clock positions d Using a 9 64 inch allen head bit tighten the screws to fix the position of the claws on the snap ring e Inserting the tips of a large retaining ring pliers Snap On PR 56A into one hole in each claw com press the snap ring and install in groove of crank case bore f Verify that the gap in the snap ring is centered below the oil hole at the top of ...

Page 234: ...outer race over bearing bore on outboard side of left crankcase half 4 Insert shaft of installer plug through left outer race and into installer base Press race into bore until firmly seated against retaining ring 5 See Figure 3 128 Insert SPORTSTER end of installer base into outboard side of left crankcase half bearing bore until base contacts outboard surface of installed left outer race 6 Posit...

Page 235: ... sprocket shaft 9 See Figure 3 130 Install shim and outer bearing a Carefully place crankcase half over sprocket shaft so that it rests flat on inner bearing b Slide new inner spacer over sprocket shaft until it contacts inner bearing race c Place new outer bearing small end downward over sprocket shaft d Assemble Sprocket Shaft Bearing Seal Installation Tool Part No HD 42579 onto sprocket shaft F...

Page 236: ... See Figure 3 132 Install pinion shaft bearing a Lubricate pinion shaft bearing with engine oil b Slip bearing on pinion shaft c Install new retaining ring in groove of pinion shaft bearing inner race 13 Install transmission See 6 12 TRANSMISSION INSTAL LATION 14 Assemble crankcase halves together a Apply a thin coat of DOW CORNING SILASTIC or 3 M 800 sealant to crankcase joint faces b Slide pinio...

Page 237: ...ll oil pump See 3 12 OIL PUMP 18 See 3 15 GEARCASE COVER AND CAM GEARS Install cam gears gearcase cover lifter guides and lift ers 19 Install cylinder head See 3 5 CYLINDER HEAD 20 Install starter See 5 7 STARTER 21 Install shift linkage 22 Install all primary drive components This includes engine sprocket primary chain complete clutch assem bly engine sprocket nut and mainshaft nut See 6 4 PRI MA...

Page 238: ...ifications 4 1 4 2 Fuel Tank Cover Fuel Tank 4 5 4 3 Air Cleaner 4 13 4 4 Carburetor 4 14 4 5 Auto Enrichener 4 21 4 6 Throttle Position Sensor 4 23 4 7 Evaporative Emissions Control System 4 24 FUEL SYSTEM 4 Table Of Contents ...

Page 239: ......

Page 240: ... 1200 RPM Engine Idle Speed fast 2000 RPM ITEM TORQUE NOTES Battery cables to terminals 60 96 in lbs 7 11 Nm Page 4 6 Enrichener stay plate 13 23 in lbs 2 3 Nm Page 4 15 Fuel cap flange to fuel tank 20 22 in lbs 2 3 Nm Page 4 12 Fuel tank to T shaped bracket 72 96 in lbs 8 11 Nm Page 4 6 Fuel valve to fuel tank 12 14 in lbs 1 2 Nm Page 4 9 Tank cover to T shaped bracket 30 36 in lbs 3 4 Nm Page 4 ...

Page 241: ...element 3 Restricted fuel tank vent system 4 High speed riding style 5 Idle speed improperly adjusted 6 Loose jets 7 Fuel level too high 8 Plugged or restricted bowl vent 9 Worn or damaged needle or needle jet 10 Vacuum piston assembly malfunction 11 Plugged air jets or passages Remedy 1 Clean or replace 2 Replace as required 3 Correct restricted hose Replace vapor vent valve 4 Modify riding habit...

Page 242: ...ly malfunction Remedy 1 Adjust operating idle speed 2 Correct as required 3 Correct restricted hose Replace vapor vent valve 4 Replace 5 Adjust clean or replace 6 Correct and clear restriction 7 Clean and clear passages 8 Clean clear and correct as required 9 Replace assembly 10 See Table 4 5 POOR HIGH SPEED PERFORMANCE Check for 1 Inlet system air leak 2 Enrichener valve not seated or leaking 3 R...

Page 243: ...iston binding 7 Piston vacuum passage plugged Remedy 1 Clear vent 2 Tighten or replace cap 3 Correct or replace spring 4 Reposition diaphragm lip 5 Replace piston diaphragm assembly 6 Clean piston slides and body or replace piston 7 Clean and clear passage PISTON DOES NOT CLOSE PROPERLY Check for 1 Spring damaged 2 Piston binding 3 Piston diaphragm ring dirty or damaged Remedy 1 Replace spring 2 C...

Page 244: ...er 1 and set aside 7 Install oil dipstick back into threaded hole in frame back bone Fuel Tank 1 See Figure 4 5 Rotate the 3 position valve handle on the fuel valve to the fully vertical position to shut the gasoline supply to the carburetor OFF 11WARNING 1WARNING Some gasoline will drain from the outlet hose when dis connected from the fuel valve Thoroughly wipe up any spilt fuel immediately Disp...

Page 245: ...eering head 2 Install tank cover 3 See Figure 4 2 At rear of fuel tank install rear flange bolt with nylon washer to fasten tank cover to clip nut on T shaped mounting bracket Tighten flange bolt to 30 36 in lbs 3 4 Nm 4 With the lipped side up place mounting ring over threaded hole in frame backbone Install oil dipstick into hole 5 Push vent tube onto nozzle of vent tube fitting Install small cab...

Page 246: ...n Expansion can cause an overfilled tank to overflow fuel through the filler cap vent onto sur rounding areas After refueling be sure filler cap is securely tightened Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury Installation 1 See Figure 4 4 Inspect o ring 2 at underside of fuel filler cap for cuts tears or signs of dete...

Page 247: ...le clockwise to the horizontal position accesses the RES ERVE supply 11WARNING 1WARNING To prevent accidental flooding of the engine or surround ing area with gasoline always turn the fuel supply valve to OFF when the engine is not running Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury NOTE To maintain a reserve supply do ...

Page 248: ...e to OFF Remove spare hose from outlet fitting 11WARNING 1WARNING Even with the fuel tank completely drained a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed Thoroughly wipe up any spilt fuel immediately Dispose of rags in a suit able manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or...

Page 249: ...en servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Inadequate safety precautions could result in death or serious injury 1 Remove seat Depress latch at bottom and pull seat up and back to remove See 2 28 SEAT 11WARNING 1WARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety...

Page 250: ...ush on threaded end to remove from holes in fuel cap flange and boot Remove fuel cap flange and boot from fuel tank 9 Maintaining hold of rollover valve remove from hole in fuel tank Exercise caution to avoid dropping valve into fuel tank 10 See Figure 4 7 Remove o ring from groove in vent tube fitting Discard o ring 11 Clean old HYLOMAR material from both sides of fuel cap boot top of fuel tank a...

Page 251: ...rther away rotate body of valve in the opposite direction A few attempts may be needed to achieve the desired result CAUTION Do not overtighten vent tube fitting or attempt to tighten with standard click type torque wrench Overtightening fitting can snap off threaded end of rollover valve possi bly causing damaged parts to fall into fuel tank 7 Using a dial type torque wrench on hex final tighten ...

Page 252: ...nt Figure 4 10 Air Cleaner Assembly 1 Cover air cleaner 2 Seal air cleaner cover 3 Clamp spring type 4 Screw 5 Spacer 6 Screw 2 7 Venturi ring 8 Air filter box 9 Breather hoses and fittings 10 PCV valve 11 Mounting bracket left side 12 Screw 2 13 Gasket carburetor 14 Mounting bracket right side 15 Rivet 2 16 Screw 4 17 Air filter 18 Screw 9 14 13 4 5 a0482x4x 3 16 15 12 11 10 8 7 6 2 1 17 18 ...

Page 253: ...ting on same side of carburetor 8 Rotate cable adjusters at handlebar to add slack to idle and throttle cables 11WARNING 1WARNING As the carburetor is removed be sure to keep assembly upright as the float bowl contains gasoline Tilting the carburetor or turning it upside down will cause the gaso line to drain onto surrounding area Gasoline is extremely flammable and highly explosive Inadequate saf...

Page 254: ...el of throttle wheel and using cable adjusters at handlebar tighten cables as necessary to keep barrel ends from dislodging Verify operation by turning throttle grip and observing cable action 6 Position cable clamp at top of cable bracket so that short end is above longer cable guide long end above shorter cable guide With clamp capturing sleeves on cable housings tighten allen head screw to fix ...

Page 255: ...ve four Phillips screws loosely installed at bottom Remove float bowl from carburetor body CAUTION Tapping the float pin out from the squared pedestal side will result in damage that requires carburetor replace ment 2 See Figure 4 12 Using a small center punch and ham mer carefully tap float pin from holes in pedestals The rounded pedestal has an interference fit to ensure that the float pin is se...

Page 256: ...ent rotation 5 Using a 5 16 inch wrench turn hex on needle jet holder to unthread from main jet bore 6 See Figure 4 13 Turn carburetor right side up to drop out needle jet which is loose in main jet bore 7 See Figure 4 14 Insert thin bladed flat tip screwdriver into slow jet bore and using slot at top of slow jet 2 unthread to remove Figure 4 13 Carburetor Bottom End 1 Float 2 Float pin 3 Fuel val...

Page 257: ... carburetor cleaner out of pin holes inboard and outboard of throttle plate Main Circuit 1 See Figure 4 15 Plugging main jet hole in carburetor throat spray carburetor cleaner into air inlet hole of main circuit While spraying verify that solution exits main jet bore at bottom of carburetor housing 2 Using a tapered rubber tipped nozzle on the air hose to prevent both loss of air pressure and to a...

Page 258: ...ber cone on valve for dirt cracks hardening or wear Inspect wireform clip for distortion Replace fuel valve assembly if any of these conditions are found e Inspect fuel valve seat in carburetor housing for dirt damage or corrosion Replace carburetor if seat damage or corrosion is present f Verify cleanliness of slow jet Be sure that all orifices are clean and open Replace jet if damaged Verify cle...

Page 259: ...d sides of pedestals 8 Perform float level check as follows a See Figure 4 16 Place carburetor on a clean flat surface with the intake manifold side down b Tilt the carburetor 15 to 20 in a counter clockwise direction until float comes to rest NOTE The measurements will be incorrect if the carburetor is tilted less than 15 or more than 20 c Using a dial vernier caliper or dial caliper depth gauge ...

Page 260: ...oke When the enrichener valve is closed about 2 5 minutes from the time the engine is first started cold the passageway that supplies the extra fuel and air is blocked and the fast idle stops May be as long as 10 min utes in very cold temperatures See Figure 4 18 When the ignition is shut off the power to the heater is cut Deactivation of the heater causes the wax element to begin to cool During s...

Page 261: ...rew to 13 23 in lbs 2 3 Nm 3 Locate 6 place Deutsch connector and install pin termi nals in chambers 1 and 2 Mate pin and socket halves of connector 4 Standing on the right side of the vehicle start air box into opening When partially installed push PCV outlet hose onto middle fitting of 3 way connector and loosely install carburetor onto manifold carburetor coupler 5 Moving to opposite side of ve...

Page 262: ...it Snap on TTXR20E loosely install two tamper resistant T20 TORX screws NOTE The tamper resistant screws are not to be tightened until the throttle position sensor has been properly adjusted See the instructions under step 6 for details 3 Locate 6 place Deutsch connector and install pin termi nals in chambers 3 through 5 Mate pin and socket halves of connector See Table 4 7 4 Insert bolt through b...

Page 263: ...hose A preformed hose on one end of the fitting is fixed to an allen head screw on the venturi ring for positive location Crankcase vapors passing through the PCV valve follow the fuel vapors to the charcoal canister via a 3 way fitting plumbed into the PCV outlet hose The fuel and crank case vapors after passing through the charcoal canister travel through the purge hose to the carburetor and lik...

Page 264: ...l canis ter For correct assembly mark tubes to correlate with stamps on canister Mark one tube CARB and the other TANK 4 Pull PCV outlet hose connection from carburetor throat and PCV valve from fitting at front of charcoal canister 5 See Figure 4 24 Slide charcoal canister rearward until backside of tongue at top of canister just contacts two legs on bracket Holding canister in position use the t...

Page 265: ...onnector inboard of the carburetor splits the path of the hose into two directions The center barb pointed at the left side of the vehicle is attached to the hose routed to the charcoal canister while the end barb is connected to a short hose that jumps to a second 3 way connector located inboard of the air box Charcoal Canister Hose The hose to the charcoal canister is routed from the center barb...

Page 266: ...g at the back of the charcoal canister One cable strap is used to connect the carb and tank vent tubes together at the back of the canis ter while another secures both tubes to the PCV outlet hose at the front of the canister NOTE On non California models the end of the tank vent tube gets routed through the slot at the front of the tail section and then into the cavity on the inboard side of the ...

Page 267: ...4 28 2004 Buell P3 Fuel System HOME NOTES ...

Page 268: ... 2 Electric Starter System 5 2 5 3 Starter Diagnostics 5 5 5 4 Starter Activation Circuits 5 7 5 5 Diagnostics Troubleshooting 5 8 5 6 Starter System Testing 5 10 5 7 Starter 5 11 5 8 Starter Solenoid 5 20 ELECTRIC STARTER 5 Table Of Contents ...

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Page 270: ......

Page 271: ...Current 400 amp max 2 4 V Stall Torque 8 1 ft lbs 11 0 Nm min 2 4 V Table 5 2 Service Wear Limits STARTER COMPONENTS 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 Page 5 19 Starter battery positive cable nut 80 100 in lbs 9 11 Nm Metric Page 5 19 Starter mounting bolts 13 20 ft lbs 18 27 Nm Page 5 19 5 ...

Page 272: ...5 1 When the starter switch is pushed the starter relay is activated and battery current 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 ...

Page 273: ...ting circuit see wiring diagram Starting circuitsee 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 during cranking Starter at moment starter switch is closed ...

Page 274: ...tting Field winding grounded Replace Armature winding grounded or short circuited Reduction gears damaged Insufficient brush spring tension Disconnected lead wire between solenoid and field windings Repair or replace lead wire Ball bearing sticks Replace bearing Battery Voltage drop due to discharged battery Charge battery Short circuit or open between electrodes Replace battery Poor contact condi...

Page 275: ...r 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 switch gear NO Repair wiring to starter button YES YES Repair wiring from starter button to relay NO YES YES NO NO 1 Perform Voltage Drop Tests between battery and Relay ...

Page 276: ...tarter button NOT pressed Replace right handlebar switch gear 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 Batter y terminal Crank engine Is voltage greater than 1 volt YES NO Repair connecti...

Page 277: ...50A 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 a0193x5x OV VDC VDC 12V OV ITEM B ITEM C ITEM D 1 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 1 Start switch 2 Relay 3 Solenoid 4 Starter 5 Battery 6 Main circuit breaker 7 Ignition switch 8 Ignition circuit breaker ...

Page 278: ...the entire difference in potential displayed on the meter NOTE Open circuits on the ground side will read zero 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...

Page 279: ...KEY SWITCH 15A LIGHTS 61 TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 4 3 2 1 CLUTCH SWITCH 95 16 Y 16 GY 16 R 2 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B 6A RATING 6A RATING 16 R B C D A F E D C B A ON OFF PARK LOCK F E D C B A KEY SWITCH LOGIC TO BATT NEG MAIN CHASSIS GROUND 4 3 2 1 MASTER C B 123 START RELAY 87A 87 85 30 86 30A 128 START RELAY FROM TO GND BATTERY R BE BK 2 1 COLOR C...

Page 280: ...roperly proceed to STARTER CURRENT DRAW TEST Starter Current Draw Test NOTES 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 a...

Page 281: ...g support bracket and primary cover See 2 21 FOOTPEGS AND FOOTPEG SUP PORT BRACKETS 5 See Figure 5 9 Remove locknut and clamp that secure oil hoses on right side of motorcycle 6 Push hoses to either side to allow access to starter 7 See Figure 5 10 Remove both starter mounting bolts and washers NOTE A ball hex driver may be required to gain access to the starter mounting bolts 8 See Figure 5 11 Re...

Page 282: ...em with engine or primary drive Starter Solenoid NOTE Do not disassemble solenoid Before testing disconnect field wire from motor terminal as shown in Figure 5 13 CAUTION Each test should be performed for only 3 5 seconds to prevent damage to solenoid NOTE The solenoid Pull in Hold in and Return tests must be per formed together in one continuous operation Conduct all three tests one after the oth...

Page 283: ... starter pinion does not remain in pull in position replace the solenoid Solenoid Return Test 1 See Figure 5 15 With test leads still connected in the manner specified at the end of the previous SOLENOID HOLD IN TEST disconnect solenoid relay terminal positive battery post test lead C at either end 2 Observe starter pinion a If starter pinion returns to its original position sole noid is working p...

Page 284: ... than 0 016 in 0 4 mm of runout should be replaced or machined on a lathe b Replace commutators when diameter is less than 1 141 in 28 981 mm c Check armature bearings Replace if necessary CAUTION Do not use sandpaper or emery cloth to remove burrs on commutator Otherwise abrasive grit may remain on commutator segments this could lead to excessive brush wear Use only the recommended crocus cloth 8...

Page 285: ...ndercutting lightly sand the com mutator with crocus cloth to remove any burrs See Figure 5 19 Mica must not be left with a thin edge next to segments Mica must be cut away clean between segments Figure 5 19 Undercutting Mica Separators Correct Incorrect a0188x5x 1 Starting groove in mica with 3 cornered file 2 Undercutting mica with piece of hacksaw blade 3 Segments 4 Mica 1 2 3 4 ...

Page 286: ...segment 1 b Touch the other probe to the armature core 2 c There should be no continuity infinite ohms If there is continuity then the armature is grounded Replace grounded armatures 11 See Figure 5 22 Check for OPEN ARMATURE with an ohmmeter or continuity tester a Check for continuity between all commutator seg ments b There should be continuity 0 ohms at all test points No continuity at any test...

Page 287: ...uity at either brush then the field coil s are open and the field frame must be replaced 14 See Figure 5 25 Test BRUSH HOLDER INSULATION with an ohmmeter or continuity tester a Touch one probe to holder plate 1 b Touch the other probe to each of the positive insu lated brush holders 2 c There should be no continuity infinite ohms If there is continuity at either brush holder replace the brush hold...

Page 288: ... End cover 4 Brush holder 5 O ring 2 6 Brush spring 4 7 Field frame 8 Field wire nut with washer metric 9 Field wire 10 Armature bearing 2 11 Armature 12 Mounting bolt 2 13 Washer 2 14 Drive housing mounting bolt 15 Gasket 16 Drive housing 17 O ring 18 Drive assembly overrunning clutch 19 Idler gear bearing cage 20 Idler gear roller 5 21 Idler gear 22 Ball 23 Return spring 24 Solenoid housing ...

Page 289: ...1 Nm c Replace protective boot 3 See Figure 5 28 Install both starter mounting bolts and washers Tighten to 13 20 ft lbs 18 27 Nm 4 Position oil hoses in clamp and install clamp to through bolt with new locknut Make sure hoses are not kinked or restricted 5 Install primary cover See 6 2 PRIMARY CHAIN 6 Fill transmission to proper level with fresh lubricant See 1 11 TRANSMISSION PRIMARY FLUID 7 Ins...

Page 290: ...nd a hollow cylinder con taining a movable plunger DISASSEMBLY 1 See Figure 5 29 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 29 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 291: ... 6 17 6 6 Transmission Case 6 18 6 7 Transmission Disassembly 6 20 6 8 Transmission Assembly 6 25 6 9 Main Drive Gear 6 29 6 10 Right Transmission Case Bearings 6 31 6 11 Left Crankcase Bearings 6 33 6 12 Transmission Installation 6 35 6 13 Shifter Pawl Adjustment 6 37 6 14 Transmission Sprocket 6 39 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 292: ......

Page 293: ...TS FINAL DRIVE TRANSMISSION TO REAR WHEEL Transmission sprocket number of teeth 27 N A Rear wheel sprocket number of teeth 80 Replace at 15 000 mi Secondary drive belt number of teeth 139 Replace at 15 000 mi Ratio 2 96 1 N A Table 6 3 Transmission Specifications ITEM NEW COMPONENTS SERVICE WEAR LIMITS TRANSMISSION Primary drive transmission lubricant capacity 32 fl oz 946 ml N A OVERALL GEAR RATI...

Page 294: ...Clutch mainshaft nut 70 80 ft lbs 95 109 Nm LOCTITE 262 red left hand threads Page 15 Crankcase 1 4 in screws 180 100 in lbs 9 0 12 4 Nm LOCTITE 262 red Page 35 Crankcase 5 16 in screws 15 19 ft lbs 20 25 Nm LOCTITE 262 red Page 35 Engine sprocket nut 190 210 ft lbs 258 285 Nm LOCTITE 262 red Page 15 Primary cover bolts 100 120 in lbs 11 14 Nm Follow torque sequence Page 6 Retention collar screw 1...

Page 295: ...es become worn it must be replaced Remove and install the chain fol lowing the procedure under 6 4 PRIMARY DRIVE CLUTCH Figure 6 1 Primary Cover and Shifter Assembly 2 3 4 5 6 7 10 18 a0104x6x 8 9 11 24 22 15 13 16 14 17 1 19 20 21 23 1 Sems screw with washer 3 2 Clutch inspection cover 3 Clutch cover gasket 4 Spring 5 Lockplate 6 Nut 7 Ramp assembly 8 Primary cover 9 Bushing 10 Spring 11 Chain gu...

Page 296: ...rews with washers and clutch inspection cover 9 Remove and discard gasket from groove in primary cover 10 Slide spring with attached hex lockplate from flats of clutch limiting screw 11 See Figure 6 3 Turn clutch adjusting screw clockwise to release ramp and coupling mechanism As the limiting screw is turned ramp assembly moves forward Unscrew nut from end of limiting screw 12 Remove hook of ramp ...

Page 297: ...e locknut The spacer is used to quickly get proper adjustment during pro duction This spacer should be removed and discarded at the first adjustment interval 1 See Figure 6 5 Back off locknut and chain limiting screw Remove spacer IMPORTANT NOTE Be certain to use Inch Pound Wrench Chain adjuster shoe can be damaged by excessive force 2 See Figure 6 6 Tighten chain limiting screw to 24 in lbs 2 7 N...

Page 298: ...l transmission to proper level with fresh lubricant See TRANSMISSION under section 1 11 TRANSMISSION PRIMARY FLUID 10 Install clutch inspection cover with new gasket and three sems screws with washers Tighten screws in a cross wise pattern to 84 108 in lbs 10 12 Nm 11 See Figure 6 1 Install rubber washer and shifter lever assembly and tighten pinch screw to 12 14 ft lbs 16 19 Nm 12 Install left fo...

Page 299: ...n adjusting screw clockwise to release ramp 7 and coupling mechanism 20 As the adjusting screw is turned ramp assembly moves forward Unscrew nut 6 from end of adjusting screw CLEANING AND INSPECTION 1 Thoroughly clean all parts in cleaning solvent 2 See Figure 6 8 Inspect three balls of release mecha nism and ball socket surfaces of inner and outer ramps for wear pitting surface breakdown and othe...

Page 300: ...elt c Adjust clutch release mechanism See 1 10 CLUTCH d Fit nut hex into recess of outer ramp 4 Install left footpeg support bracket See 2 21 FOOT PEGS AND FOOTPEG SUPPORT BRACKETS 11WARNING 1WARNING 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 deat...

Page 301: ...ll be transmitted to the rear wheel When the clutch is disengaged clutch lever pulled to left han dlebar grip the pressure plate is pulled outward by clutch cable action against the diaphragm spring thereby com pressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch plates together The fiber plates are now free to rotate at a dif ferent rel...

Page 302: ...phragm spring 2 c Install bearing 5 and washer 6 d Thread the tool handle 1 onto end of forcing screw 4 CAUTION See Figure 6 13 Turn compressing tool handle only the amount required to release spring seat and remove snap ring Excessive compression of diaphragm spring could damage clutch pressure plate 5 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw flats to pre...

Page 303: ...ramp 5 Ball 3 6 Inner ramp 7 Retaining ring 8 Coupling 9 Retaining ring 10 Spring seat 11 Diaphragm spring 12 Retaining ring 13 Release plate 14 Retaining ring 15 Bearing 16 Adjusting screw 17 Pressure plate 18 Friction plate paper 5 19 Steel plate 5 20 Mainshaft nut 21 Washer labeled out 22 Clutch hub 23 Retaining ring 24 Bearing 25 Clutch shell and sprocket 26 Retaining ring 18 ...

Page 304: ...to pressure plate a See Figure 6 15 Align two tabs on perimeter of release plate with corresponding recesses in pres sure plate b See Figure 6 16 Secure the adjusting screw assembly with large retaining ring 8 Attach tools to compress clutch diaphragm spring See Step 2 of CLUTCH PACK under 6 4 PRIMARY DRIVE CLUTCH 9 Remove clutch pack components See Steps 3 4 of CLUTCH PACK under 6 4 PRIMARY DRIVE...

Page 305: ...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 for cracks or bent tabs Install a new spring if either condition exists 3 See Figure 6 17 Check fiber plates for thickness a Wipe the lubricant from the five fiber plates and stack them on top of each other b Measure the t...

Page 306: ...oard side of spring seat and fully seated in groove of clutch hub carefully loosen and remove compression tool Primary Drive 1 See Figure 6 20 Assemble clutch hub and shell if neces sary a Press new bearing in clutch shell Secure bearing with a new retaining ring b Press inboard end of clutch hub into shell bearing Secure with new retaining ring on end of hub 2 Assemble pressure plate hardware a S...

Page 307: ...sting screw assembly into pressure plate a See Figure 6 15 Align two tabs on perimeter of release plate with corresponding recesses in pres sure plate b See Figure 6 16 Secure the adjusting screw assembly with retaining ring 6 Install primary cover See 6 2 PRIMARY CHAIN 7 Install left footpeg support bracket See 2 21 FOOT PEGS AND FOOTPEG SUPPORT BRACKETS 11WARNING 1WARNING Always connect positive...

Page 308: ...6 16 2004 Buell P3 Drive Transmission HOME NOTES ...

Page 309: ...he crankcase Figure 6 23 Transmission Power Flow 4 1 3 2 5 4 1 3 2 5 4 1 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 Mainshaft 3rd Gear Countershaft Mainshaft Out 2nd Gear Countershaft Mainshaft In In 4th Gear Countershaft Mainshaft In Out 5th Gear Countershaft Mainshaft Out In b1068x6x Countershaft In ...

Page 310: ...ngine sprocket See 6 4 PRIMARY DRIVE CLUTCH 8 See Figure 6 24 Place transmission in gear Remove countershaft TORX screw 4 and retention collar 3 9 See Figure 6 25 Detach spring 11 from groove in post 10 Remove retaining ring 10 and detent plate 9 Discard retaining ring 10 You will need to use a new retaining ring for installation 11 Remove starter See 5 7 STARTER 12 See Figure 6 25 Remove two lock...

Page 311: ... See Figure 6 27 Separate crankcase halves Figure 6 26 Crankcase Hardware 1 Screw 4 2 Washer 4 3 Rear isolator 4 Dowel pin 5 Hex socket head screw 9 6 Washer 14 7 Bottom case t40 TORX bolt 5 8 Hex socket head screw 9 Spacer 10 Crankcase set 11 Nyloc hex locknut 12 Washer a0484x6x 12 10 4 5 8 7 6 6 9 11 3 1 2 Figure 6 27 Splitting Crankcase Halves 7694 ...

Page 312: ...ankcase and transmission assembly from engine stand 3 See Figure 6 29 Place crankcase half 3 and transmis sion assembly 4 on arbor press 1 and support trans mission assembly on parallel supports 5 4 Press transmission assembly using TRANSMISSION REMOVER 2 Part No B 43985 1 to remove transmis sion assembly from crankcase half 5 Remove crankcase from fixture Figure 6 28 Transmission Assembly 7693 Fi...

Page 313: ... in the other direction 4 Remove shifter forks 16 17 18 Figure 6 30 Shifter Mechanism 1 Right crankcase half 2 Mainshaft bearing 3 Countershaft bearing 4 Plate 5 Pin 6 Detent arm 7 Detent screw 8 Detent plate 9 Retaining ring 10 Shifter shaft assembly 11 Locknut 2 12 Washer 2 13 Shifter pawl 14 Cotter pin 3 15 Shifter fork pin 3 16 Shifter fork 4th gear 17 Shifter fork 1st 2nd gear 18 Shifter fork...

Page 314: ...direction 1 See Figure 6 31 As each component is removed place it on a clean surface in the exact order of removal Figure 6 31 Recording The Order of Disassembly b0948x6x Figure 6 32 Transmission Assembly Right Crankcase Half 1 Bearing inner 2 Fifth gear mainshaft 3 Bearing outer 4 Oil seal 5 Right crankcase half 6 Ball bearing 7 Retaining ring 8 Quad seal 9 Spacer 10 Oil seal 11 Bearing closed en...

Page 315: ... 10 Thrust washer 6 11 Retaining ring 7 12 1st gear mainshaft 13 3rd gear mainshaft 14 2nd gear mainshaft 15 Spacer 16 4th gear countershaft 17 1st gear countershaft 18 Countershaft 19 3rd gear countershaft 20 2nd gear countershaft 21 5th gear countershaft 22 Bearing 23 Retaining ring 24 Countershaft retainer 25 Screw a0126x6x 15 5 4 3 2 1 22 23 24 25 11 10 11 21 20 8 10 11 19 18 11 10 17 8 14 11 ...

Page 316: ...2 Remove split bearing 8 that was under countershaft 2nd gear 20 and thrust washer 10 including retaining ring 11 on the countershaft 6 Slide countershaft 3rd 19 gear off free end of shaft 18 3 Remove beveled washer spacer 15 and countershaft 4th gear 16 4 Expand retaining ring 11 located next to countershaft 1st gear 17 Remove retaining ring 11 and thrust washer 10 Slide countershaft 1st gear 17 ...

Page 317: ...2nd gear 14 onto shaft with the fork groove facing 3rd gear 13 COUNTERSHAFT SUB ASSEMBLY 1 See Figure 6 34 Install new retaining ring 11 and thrust washer 10 onto countershaft 18 in the second ring groove from the end 2 Install split bearing 8 onto countershaft 3 Locate countershaft 1st gear 17 which can be identi fied by the two radial grooves at one side Slide gear 17 onto shaft Position gear ov...

Page 318: ... 10 Thrust washer 6 11 Retaining ring 7 12 1st gear mainshaft 13 3rd gear mainshaft 14 2nd gear mainshaft 15 Spacer 16 4th gear countershaft 17 1st gear countershaft 18 Countershaft 19 3rd gear countershaft 20 2nd gear countershaft 21 5th gear countershaft 22 Bearing 23 Retaining ring 24 Countershaft retainer 25 Screw a0126x6x 15 5 4 3 2 1 22 23 24 25 11 10 11 21 20 8 10 11 19 18 11 10 17 8 14 11 ...

Page 319: ...eutral position CAUTION To prevent possible cotter pin damage the pins must be inserted through the shifter forks as shown in the inset of Figure 6 36 6 Align the hole through the top of each shifter fork with the appropriate cam groove in the shifter drum Lubricate pins with Sport Transmission Lube Drop pins through the holes in shifter forks With a small screwdriver press on the pins while manip...

Page 320: ...ing 4 Plate 5 Pin 6 Detent arm 7 Detent screw 8 Detent plate 9 Retaining ring 10 Shifter shaft assembly 11 Locknut 2 12 Washer 2 13 Shifter pawl 14 Cotter pin 3 15 Shifter fork pin 3 16 Shifter fork 4th gear 17 Shifter fork 1st 2nd gear 18 Shifter fork 3rd 5th gear 19 Shifter fork drum 20 Neutral indicator pin 4 8 9 a0118x6x 18 15 13 10 11 12 7 6 5 3 2 1 16 17 20 19 14 15 14 15 14 14 ...

Page 321: ...nsert bolt 2 through cross plate 1 and 5th gear 3 CAUTION When removing the main drive gear 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 9 At outside of case place driver 4 and thrust washer 5 over end of bolt 2...

Page 322: ...39 mm c Press in the inner bearing to a depth of 0 080 in 2 032 mm INSTALLATION 1 Replace main drive gear bearing 2 See Figure 6 41 Use MAIN DRIVE GEAR REMOVER AND INSTALLER Part No HD 35316 A 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 end of ...

Page 323: ...n 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 bearing open end first next to the bea...

Page 324: ...Right Crankcase Half 1 Bearing 2 2 Fifth gear mainshaft 3 Needle bearing 2 4 Oil seal 5 Right crankcase half 6 Ball bearing 7 Retaining ring 8 Quad seal 9 Spacer 10 Oil seal 11 Bearing closed end shifter drum 12 Bearing closed end countershaft a0127x6x 5 9 8 7 6 4 3 2 1 10 11 12 ...

Page 325: ...t Bearings 1 Place crankcase on press with inside surface of crank case 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 retaining ring with beveled side facing away from bearing Shift Drum Bu...

Page 326: ... 10 Thrust washer 6 11 Retaining ring 7 12 1st gear mainshaft 13 3rd gear mainshaft 14 2nd gear mainshaft 15 Spacer 16 4th gear countershaft 17 1st gear countershaft 18 Countershaft 19 3rd gear countershaft 20 2nd gear countershaft 21 5th gear countershaft 22 Bearing 23 Retaining ring 24 Countershaft retainer 25 Screw a0126x6x 15 5 4 3 2 1 22 23 24 25 11 10 11 21 20 8 10 11 19 18 11 10 17 8 14 11 ...

Page 327: ...ransmis sion assembly and install TRANSMISSION INSTALLER Part no B 43985 3 into crankcase 3 See Figure 6 49 Press crankcase into transmission assembly until it bottoms out 4 Remove transmission assembly and left crankcase half from fixture 5 See Figure 6 50 Assemble crankcase halves together a Apply a thin coat of DOW CORNING SILASTIC or 3 M 800 sealant to crankcase joint faces b See CRANKCASE HAL...

Page 328: ...ankcase Hardware 1 Screw 4 2 Washer 4 3 Rear isolator 4 Dowel pin 5 Hex socket head screw 9 6 Washer 14 7 Bottom case t40 TORX bolt 5 8 Hex socket head screw 1 9 Spacer 1 10 Crankcase set 11 Nyloc hex locknut 12 Washer 1 a0484x6x 12 8 7 6 9 11 1 2 3 4 5 6 10 ...

Page 329: ... 116 in dia through hole in detent plate 4 and between pawl 2 and drive pin at end of shifter drum shaft c Push down top of crank 3 to remove all clearance between pawl and drill bit this will correctly align pawl to shift drum pins do not push down with too great a force as this might cause the shifter drum to rotate d With bit in place tighten shifter shaft assembly bot tom locknut 1 first to 90...

Page 330: ...ently tap seal into bore of case until the outside of seal is flush with outer edge of bore NOTE It is acceptable to recess seal to about 0 030 in 0 762 mm below outer edge of bore Seal will be controlled by tool 8 See Figure 6 54 Position retention collar next to end of counter shaft with beveled side facing outward a Apply several drops of LOCTITE 243 blue to last few threads b Insert screw 1 th...

Page 331: ...h secondary drive belt onto main drive gear shaft 1 2 Place transmission in neutral 3 Apply a few drops of LOCTITE 262 red to the left hand threads of transmission sprocket nut 3 and lightly coat the washer faced side with clean H D 20W50 engine oil Wipe off any excess oil 4 Position nut with washer faced side facing transmission sprocket Turn the nut counterclockwise to install it onto main drive...

Page 332: ...screw holes If you cannot align lockplate and sprocket screw holes nut may be additionally tightened 45 as specified above Tightening too much or too little may cause the nut to come loose during vehicle opera tion 10 If you cannot align lockplate and sprocket screw holes nut may be additionally tightened until screw holes align 11 See Figure 6 55 Install two socket head screws through aligned hol...

Page 333: ...arter Ignition Interlock 7 26 7 12 Diodes 7 33 7 13 Charging System 7 34 7 14 Alternator 7 40 7 15 Voltage Regulator 7 43 7 16 Battery 7 44 7 17 Headlamp 7 49 7 18 Tail Lamp 7 51 7 19 Turn Signals 7 52 7 20 Turn Signal Flasher 7 54 7 21 Handlebar Switches 7 55 7 22 Horn 7 57 7 23 Neutral Indicator Switch 7 58 7 24 Fuses And Circuit Breakers 7 59 7 25 Electronic Speedometer 7 60 7 26 Speedometer Se...

Page 334: ......

Page 335: ... Cable 2 375 5 833 ohms Table 7 7 Ignition Timing Spark Occurrence RPM TP SENSOR LOW VOLTAGE PT HIGH VOLTAGE WOT 1200 RPM Idle 20 BTDC 18 BTDC 3000 RPM 30 BTDC 18 BTDC 6000 RPM 45 BTDC 35 BTDC Curve Switch Point TP Sensor Input 2 4V Rev Limit 6500 RPM Table 7 8 Electrical Specifications ELECTRICAL SYSTEM AMPERES Main Circuit Breaker 30 Ignition Fuse 7 5 Light Fuse 15 Accessory Fuse 7 5 System Fuse...

Page 336: ...m LOCTITE 243 Page 7 58 Rotor cup mounting fasteners 43 53 in lbs 5 6 Nm Page 7 20 Rotor mounting bolts 90 110 in lbs 10 2 12 4 Nm LOCTITE 242 Page 7 42 Sidestand switch fasteners 30 36 in lbs 3 4 4 Nm Page 7 30 Spark plug 11 18 ft lbs 14 9 24 4 Nm Page 7 3 Speedometer sensor screw 80 100 in lbs 9 11 3 Nm Page 7 62 Stator mounting screws 30 40 in lbs 3 4 4 5 Nm T 27 TORX with retaining compound re...

Page 337: ...ear case cover The module has two functions First it computes the spark advance for proper ignition timing Second it opens and closes the low voltage circuits between the battery and igni tion coil to produce high voltage discharge to the spark plug The ignition module on the P3 Blast also contains an inte grated cam position sensor Above 6500 RPM the ignition module will automatically reduce powe...

Page 338: ...the right side of the motorcycle The rotor is mounted on the camshaft and operates at one half crankshaft speed As the rotor turns a slot in its outside diameter breaks the magnetic field of a Hall effect device mounted on the cam position sensor The output of the Hall effect device is a logic type signal that corresponds to the timing information from the spinning rotor This technique gives accur...

Page 339: ...Y M ASTER C B 1 2 3 4 M AIN CHASS I S GRO UND TO BATT NEG GY 1 2 3 4 5 6 AUTO ENRI CH THROTT LE PO SI TION SENSOR KB LBE Y 15A 7 5A 7 5A 7 5A 95 CLUTCH SW I TCH 10 83 PK IGN M ODULE GN BK W R W BK W BK R W BK PK W BK V W KB BK TN Y V O FROM 3 R R R B 1 R 1 R 1 R GY GY V O O W V W V KB S14 22 TN Y R B 1 R R O SW I TCH NEUTRAL 131 TN R 2 R 2 R BK BK TN GN BK R BK R IGN POW ER BE R BK1 TN TN W R 2 TN...

Page 340: ...1 5001 Measure Voltage At Connector 22A Pin 4 GY Battery Voltage Present NO Repair Open GY Wire Between 22 and Fuse YES 5002 With Connector 22 Mated And Ignition On Measure Voltage At Connector 22A Pins 2 and 3 W BK Battery Voltage Present NO Repair Replace Engine Stop Switch or Wiring YES Repair Open W BK Wire Between Coil and 22A 5002 5173 PK PK W BK W BK Go To Next Page No Description Type Loca...

Page 341: ...o BK Pin 6 On 10B Multimeter Should Register 12VDC 1 0 VDC 10 1 2 3 4 5 6 YES Check Continuity Between Pin 1 W BK 10B And Coil W BK Wire Continuity Present NO YES Repair Open In W BK Wire NO Repair Open Between 10B Pin 6 BK And Ground 5003 5003 Go To Next Page YES Perform Coil Resistance Check If Capacitor Is Not Available NO YES NO YES YES NO 5003 1 1 5000 5051 C B A 83A Coil 1 NOTE Male connecto...

Page 342: ... Remove Timer Cover See Ignition Module Cam Position Sensor for procedure Crank Engine Is LED Flashing NO Is Rotor Cup Rotating Replace Ignition Module YES YES NO Replace Ignition Module Remove Gearcase Cover Inspect For Mechanical Failure Repair 5009 5009 5005 Harness Adapters HD 42962 3 3 3 7793 10 NOTE Male connectors are labeled A Female connectors are labeled B Inspect ignition module for sig...

Page 343: ... socket 5 LT GN GY on connector 10B Continuity present YES NO Check starter interlock Check continuity to ground on LT GN GY wire socket A connector 134B or 10B Is continuity present 5007 Check continuity to ground on TN Y wire socket B connector 134B Is continuity present YES NO Inspect module harness for damage Repair if necessary If harness is not damaged replace ignition module Repair short to...

Page 344: ...et C GY And Socket B BK Is Voltage 11 13 VDC NO Is Bank Angle Sensor Correctly Installed Repair Open In GY Wire Between Bank Angle Sensor And Ignition Fuse Are Ferrous Metals Located Within 0 250 in 6 4 mm Of Sides Face Or Top Of Bank Angle Sensor YES NO Install Properly Return To Original Configuration NO Replace Bank Angle Sensor YES 5007 5013 ...

Page 345: ...iming set correctly Check Auto Enrichener Adjust timing YES YES YES YES YES NO NO NO NO NO Closed throttle voltage 0 55V or 0 45V 0V 12V No Change Erratic or greater than 3 7V and less than 12V Recalibrate TP Sensor Check resistance between Pin 3 and ground Is resistance less than 1 Locate and repair Short to voltage Check continuity between breakout box pin 5 and connector 88B pin 5 Continuity pr...

Page 346: ...2962 and BREAKOUT BOX Part No HD 42682 using black connectors between connector halves 88A and 88B f Turn ignition switch to ON Using a multimeter mea sure voltage between pin 3 V W and pin 5 BK g Adjust rotate throttle position sensor TPS until voltage reading is 0 5V 0 05V h Completely open and close the throttle by rotating the throttle control through its full range of motion Wide Open Throttl...

Page 347: ...post engages hole in trunk to ensure proper alignment of sensor 3 Install bank angle sensor with allen screw and locknut Tighten screw to 25 27 in lbs 2 8 3 1 Nm 4 Install circuit breaker to circuit breaker mounting bracket 11WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a ba...

Page 348: ...e drained of its charge if the vehicle is left standing too long NOTE The key locks the ignition system and is removable in both the OFF FORK LOCK and P PARK positions The PARK position is located between the OFF and IGNITION positions and allows the rider to remove the key while leaving the lights on When the key is placed in the PARK position several indi cator markers are or can be activated Se...

Page 349: ...y switch connector 33 to main wiring harness 6 Install four screws and washers to attach windscreen to mounting brackets See 2 26 WINDSCREEN 7 Install negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 6 8 10 8 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 operatio...

Page 350: ...hment cycle even after hot restart If enrichment cycle exceeds 5 minutes see diagnostic chart on following page See 4 5 AUTO ENRICHENER for information on replacing the auto enrichener See diagnostic chart on next page for troubleshooting infor mation NOTE Auto Enrichener wire colors may vary from those listed in Table 7 14 Figure 7 15 Throttle Position Sensor Table 7 14 Electrical Connector 88 CH...

Page 351: ...tor 88 to carburetor Check continuity from Pin 1 on connector 88 to Pin 3 on connector 10B Is continuity present Is battery voltage present at both terminals of system fuse YES NO Locate and repair Open on Orange wire between system fuse and connector 88 1 Terminal Neither Terminal Locate and repair Open between system relay and system fuse Check for continuity to ground at Pin 2 on connector 88 C...

Page 352: ...right side of motorcycle 4 See Figure 7 17 Disconnect connector 10 located on the left side of the frame backbone 5 Note position of each wiring terminal in plug end of con nector 6 Remove connector terminal pins See B 2 DEUTSCH ELECTRICAL CONNECTORS 11WARNING 1WARNING Always wear proper eye protection when drilling Flying debris could result in serious eye injury CAUTION Drilling hole in cover in...

Page 353: ...ws 2 3 Module plate ignition module cam position sensor 4 Screw rotor cup 5 Rotor cup 6 10r12 spark plug 7 Spark plug cable 8 Ignition coil 9 Connector 88 10 Auto enrichener 11 Tamper resistant T20 TORX screws 12 Throttle position sensor TP sensor 13 Connector 10 14 Bank angle sensor 12 1 3 5 6 7 8 14 13 10 9 4 2 11 ...

Page 354: ...at secures hoses and wire har ness on right side of motorcycle 7 Install module plate with two screws Do not tighten screws 8 Install negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 6 8 10 8 Nm 9 Check ignition timing See IGNITION TIMING 10 Tighten module plate screws to 10 20 in lbs 1 2 Nm 11 Install new outer timer cover 11WARNING 1WARNING After installing seat pull u...

Page 355: ...ck and engine failure 6 See Figure 7 21 Timing light will flash each time an ignition system spark occurs Aim timing light into timing inspection hole The advance timing mark two dots should be centered in timing inspection hole a If this is the case ignition timing is properly adjusted Go to Step 11 b If timing mark is not centered or is not visible in the timing inspection hole see to Steps 7 12...

Page 356: ...e When air is no longer expelled from hole both valves are closed and engine should be close to TDC and between compression and power stroke 6 Shift transmission into fifth gear and standing on left side of vehicle slowly rotate rear wheel in direction of for ward motion counter clockwise until front intake valve opens and closes 7 See Figure 7 22 Rotate rear wheel from right side of vehicle in di...

Page 357: ...park plug The high voltage discharge produces a spark to bridge the electrode gap of the spark plug The ignition coil fires the spark plug at the end of the com pression stroke no waste spark TROUBLESHOOTING Follow the troubleshooting procedures listed under 7 8 IGNI TION MODULE AND CAM POSITION SENSOR if the engine will not start is difficult to start or runs roughly Also check condition of the s...

Page 358: ...y 2 Disconnect negative battery cable from battery terminal 3 Remove fuel tank cover See 4 2 FUEL TANK COVER FUEL TANK 4 Remove left side cover 5 See Figure 7 24 Disconnect spark plug cable from coil plug post 6 See Figure 7 27 Disconnect coil connector 83 7 Remove two screws and washers and coil INSTALLATION 1 See Figure 7 24 Apply LOCTITE 243 Blue to threads of two mounting screws 2 Attach coil ...

Page 359: ...n itself Pulling on the cable will damage the cable s carbon core Disconnect spark plug cable from ignition coil and spark plug terminal Inspect removed cable for damage INSPECTION 1 See Figure 7 28 Inspect spark plug cable Replace cable if worn or damaged a Check for cracks or loose terminals b Check for loose fit on ignition coil and spark plug 2 Check cable boot cap for cracks or tears Replace ...

Page 360: ...e will not run Grounds may be established three ways By retracting the sidestand and grounding through the sidestand switch See Ignition Test 1 on following page to check sidestand switch function By placing the motorcycle in neutral and grounding through the neutral switch See Ignition Test 2 on follow ing page to check neutral switch function By disengaging the clutch and grounding through the c...

Page 361: ...O Repair Wiring Repair open TN W wire or TN Y wire between connector 60 and Diode 2 NO Replace Sidestand Switch 5053 5054 5055 1 Use gray male probe and patch cord Part No HD 41404 1 YES Ground present on TN W wire at connector 60 YES from TEST CONNECTOR KIT YES YES Check Diode 1 with ohmmeter Diode OK Remove sprocket cover Check for ground at neutral switch terminal Ground present Check for groun...

Page 362: ... Reverse polarity Replace diode YES Repair open on TN GN wire between connector 95 and Diode 2 NO Replace clutch switch NO NO Repair open on BK wire between connector 95 and ground NO 5071 5072 5073 5074 5075 1 2 Check for ground on BK wire of connector 95 Ground present NO NO Repair Wiring System OK YES Remove Seat Remove fuse block from frame tab Turn fuse block upside down to access terminals M...

Page 363: ...Y SWITCH 15A LIGHTS 61 TOP VIEW BLOCK FUSE RELAY SYSTEM 87A 87 85 30 86 4 3 2 1 CLUTCH SWITCH 95 16 Y 16 GY 16 R 2 18 O W 16 R BK ZADI KEY SWITCH 12A RATING 16 GN B 6A RATING 6A RATING 16 R B C D A F E D C B A ON OFF PARK LOCK F E D C B A KEY SWITCH LOGIC TO BATT NEG MAIN CHASSIS GROUND 4 3 2 1 MASTER C B 123 START RELAY 87A 87 85 30 86 30A 128 START RELAY FROM TO GND BATTERY R BE BK 2 1 COLOR COD...

Page 364: ... 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 365: ... 38 Remove acorn nuts nuts with lock washers and wire leads from circuit breaker studs Tag wire leads for ease of assembly 4 See Figure 7 37 Remove circuit breaker from circuit breaker bracket by carefully prying tab located on left side open and sliding circuit breaker out NOTE Bank Angle Sensor will require reinstallation if bracket is removed See 7 5 BANK ANGLE SENSOR 5 Install in the reverse o...

Page 366: ... with the circled num bers in the 7 11 STARTER IGNITION INTERLOCK flow charts 1 Check diode with an ohmmeter as shown in Figure 7 40 2 Check diode polarity as shown in Figure 7 41 3 Replace diodes as necessary Figure 7 39 Fuse Block Figure 7 40 Ohmmeter Diode Test TN W TN R DIODE 1 R2 R BK 15A 15A 15A SYSTEM LIGHTS 15A KEY SWITCH DIODE 2 SPARE TN Y TN GR O 7 5A SPARE 7 5A 7 5A ACCESSORY IGNITION T...

Page 367: ...e by pulling it straight up off the relay block INSTALLATION 1 See Figure 7 42 Install the new diodes into position on the fuse block by pushing it into the slot 2 Connect negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 7 11 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...

Page 368: ... to charge or does not charge at a satisfactory rate make the following recommended checks Battery Check for a weak or dead battery See 7 16 BATTERY Bat tery 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 45 Voltage Regulator Inspection See Figure 7 43 The voltage regulator base must have a clean t...

Page 369: ...form Stator Check Fail Perform Current and Voltage Output Test Record measurements and compare with Total Current Draw Test before proceeding Fail Replace regulator Isolate damaged component or wiring Fail Fail Isolate damaged wiring or excessive accessories Replace regulator Fail Fail Pass Perform Voltage Output Test Fail Perform AC Output Check Fail Inspect rotor Replace regulator Fail Replace r...

Page 370: ...128 BK 2 BK BK 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 a0278x7x Voltage Regulator Stator Battery Main Circuit Main Chassis Ground Starter Breaker ...

Page 371: ... considered and checked for excessive drain NOTE A battery with a surface discharge condition could suffer a static drain Correct by cleaning battery case Total Current Draw Test If battery runs down during use the current draw of the motorcycle components and accessories may exceed output of the charging system 1 See Figure 7 47 To check for this condition place load tester induction pickup or cu...

Page 372: ... higher regulator is not functioning properly or connections are loose or dirty Stator Check 1 Turn ignition key switch to OFF 2 See Figure 7 49 Connect an ohmmeter a Locate voltage regulator connector 46 behind left footrest support 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 ...

Page 373: ...tator sockets 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 Figure 7 51 Chec...

Page 374: ... clutch assembly primary chain and engine sprocket rotor assembly as a unit See 6 4 PRIMARY DRIVE CLUTCH 5 Remove disassemble rotor and or stator as required Refer to the following procedures Rotor 1 See Figure 7 52 Remove the eight bolts which secure alternator rotor to engine sprocket 2 See Figure 7 53 Position blocking under rotor Press sprocket free of rotor NOTE Resistance to sprocket rotor d...

Page 375: ...esult in alternator damage 5 Remove stator wiring grommet from left crankcase half 6 Withdraw stator wiring from grommet hole in left crank case half Remove stator CLEANING AND INSPECTION CAUTION Do not strike or drop alternator rotor or damage to mag net adhesive could occur Magnet adhesive damage can result in rotor failure 1 Clean rotor with a petroleum base solvent Remove all foreign material ...

Page 376: ... wiring 5 Connect alternator stator wiring to voltage regulator con nector 46 located behind left footrest support 6 See Figure 7 55 Attach rotor to sprocket a Position rotor on sprocket Align holes in sprocket with holes in rotor b Apply a drop of LOCTITE 243 blue to threads of each mounting bolt Insert the eight mounting bolts through rotor and start bolts into tapped holes in sprocket c Positio...

Page 377: ...ircuit breaker b Route charging wire back to voltage regulator 5 Remove two mounting screws 6 Remove and discard voltage regulator INSTALLATION 1 Apply LOCTITE 243 Blue to threads of two mounting screws 2 See Figure 7 57 Attach new voltage regulator using two screws Tighten screws to 48 72 in lbs 5 8 Nm 3 Connect voltage regulator connector 46 to alternator stator wiring Cable strap connector halv...

Page 378: ...seri ous injury See Figure 7 59 All 2004 Model Year Buell batteries are permanently sealed maintenance free valve regulated lead calcium and sulfuric acid batteries The batteries are shipped pre charged and ready to be put into service Do not attempt to open these batteries for any reason Table 7 18 Battery Electrolyte Antidotes CONTACT SOLUTION External Flush with water Internal Drink large quant...

Page 379: ...ng 11WARNING 1WARNING Always turn the battery load tester OFF before connect ing the tester cables to the battery terminals Connecting tester cables with the load tester ON could cause a spark resulting in a battery explosion which could result in death or serious injury 3 See Figure 7 60 Connect tester leads to battery posts and place induction pickup over negative black cable CAUTION To avoid lo...

Page 380: ... 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 battery red posi tive lead to the positive terminal and black negative lead to the negative terminal If the battery is still in the vehicle connect the negative lead to the chassis ground Be sure that the ignition and all el...

Page 381: ...rks may cause a battery explo sion which could result in death or serious injury CAUTION Overtightening bolts can damage battery terminals 2 See Figure 7 61 Insert bolt through battery positive cable red into threaded hole of battery positive ter minal 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 bol...

Page 382: ...epends on the ambient temperature and the battery s state of charge Batteries dis charge at a faster rate at higher ambient temperatures To reduce the self discharge rate store battery in a cool not freezing dry place Charge the battery every month if stored at temperatures below 60 F 16 C Charge the battery more frequently if stored in a warm area above 60 F 16 C NOTE The H D Battery Tender Autom...

Page 383: ...crews and detach spring from nest 4 Remove headlamp brackets a Remove front turn signals See 7 19 TURN SIG NALS b Remove two screws from bracket c Repeat for other bracket d Remove front forks and headlamp brackets See 2 17 FRONT FORK e Remove windscreen from brackets See 2 26 WIND SCREEN ASSEMBLY INSTALLATION Headlamp Housing and Brackets 1 Install headlamp brackets a Install front forks through ...

Page 384: ...s 3 Install bezel to retaining ring with three phillips screws Tighten screws to 12 14 in lbs 1 2 Nm 4 Install windscreen with four screws and washers See 2 26 WINDSCREEN 11WARNING 1WARNING Check for proper headlamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper headlamp operation could result in death or serious injury 5 See Figure 7 64 ...

Page 385: ...2 Attach the tail lamp connector to the back of the tail lamp 11WARNING 1WARNING Check for proper tail lamp operation before riding motor cycle Visibility is a major concern for motorcyclists Fail ure to have proper tail lamp operation could result in death or serious injury 3 Check tail lamp for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ...

Page 386: ... as shown in Figure 7 66 3 Install four screws washers and windscreen See 2 26 WINDSCREEN 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 4 Check turn signals for proper operation If operation fails reread procedure and verify that...

Page 387: ...bility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 4 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 ...

Page 388: ...eaker to clip 4 Connect negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 6 8 10 9 Nm 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 5 Check turn signals for proper operation If operation fails reread pro...

Page 389: ...ebar by engaging stud on front housing with hole in handlebar Fasten housings with two screws Tighten to 25 33 in lbs 2 8 3 7 Nm 3 See Figure 7 71 Route switch housing wiring harness between front forks Attach connector 170 and connec tor 22 to wiring harness Fasten wiring harness behind dash with new cable straps 4 Adjust throttle cables See 1 19 THROTTLE CABLES 11WARNING 1WARNING Check all handl...

Page 390: ...ils reread procedure and verify that all steps were performed a Turn ignition key switch to IGN b Check headlamp LOW and HIGH beam settings c Set headlamp to LOW beam Press passing lamp switch Headlamp should flash HIGH beam for as long as the switch is pressed d Check left and right turn signals e Activate horn by pressing horn switch f Turn ignition key switch to OFF Figure 7 73 Left Handlebar S...

Page 391: ... 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 75 Remove Y BK power and BK ground wires from terminal clips b Connect voltmeter positive lead to Y BK wire c Connect voltmeter negative ...

Page 392: ...ove two socket head screws 7 and lockplate 6 CAUTION Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft Transmission sprocket nut will be damaged if turned counterclockwise to remove 4 See Figure 7 77 Remove transmission sprocket nut 5 from main drive gear shaft 3 5 Remove transmission sprocket 4 with secondary drive belt from main dr...

Page 393: ...condition exists To replace the circuit breaker 1 Remove seat See 2 28 SEAT 11WARNING 1WARNING Always disconnect the negative battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion that could result in death or serious injury 2 Disconnect battery negative cable from battery 3 Remove acorn nuts nuts with l...

Page 394: ... reset switch in The normal power up sequence will occur before entering the diagnostic mode Diagnostic codes set during this power up sequence will be stored as well NOTE Make sure no Diagnostic Codes are indicated before reset is held in for more than 5 seconds or diagnostic information will be lost When in the diagnostic mode the odometer will display the first diagnostic code When the trip swi...

Page 395: ... e Apply more glass cleaner in gap and work speed ometer free from dash 4 Depress tab and remove speedometer connector 39 INSTALLATION 1 Install connector 39 on back of speedometer 2 Lubricate rubber mount with glass cleaner and insert speedometer into dash panel 3 Install speedometer to dash panel with two screws in back of dash panel 4 Connect connector 20 and replace cable strap to adja cent wi...

Page 396: ...especially during break in Always clean and troubleshoot speedometer sensor and verify proper operation before replacing speedometer See Speedometer Sensor Test Clean any debris from speedometer sensor INSTALLATION 1 Install speedometer sensor in engine case 2 Install screw and tighten to 80 100 in lbs 9 11 Nm 3 Connect connector 65 in right side frame cavity 11WARNING 1WARNING After installing se...

Page 397: ...eedometer Operation Test 1 See Figure 7 86 Locate the 3 place Deutsch connector 65 for the speedometer sensor to right of battery and disconnect 2 Attach speedometer tester connector to speedometer sensor connector 3 Place speedometer tester power switch in the ON posi tion Place signal switch in the OUT position 4 Turn vehicle ignition switch ON 5 Begin test a Press ENTER on the tester keypad b E...

Page 398: ...ire in connector 65B Then check for continuity to ground on black wire in con nector 65B 1 Raise rear wheel off floor using REAR WHEEL SUP PORT STAND Part No B 41174 2 Install the test harness between the speedometer sensor connectors 65A and 65B 3 Place speedometer tester power switch in the ON posi tion Place signal switch in the IN position 4 Plug the speedometer tester into the test harness Tu...

Page 399: ...oggle switch again 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 ...

Page 400: ...rve output speed on speedometer while moving shaking vehicle harness connections Outputs erratic YES Replace speedometer Bad connection found Repair con nector or harness YES NO YES Go to Speedometer Test Chart 2B STOP 6008 6004 6006 6008 Go to applicable code in chart d0x YES NO 1 2 1 3 Locate and repair open in O W wire NO Locate and repair open in BK wire 6008 Replace speedometer 6014 YES Repai...

Page 401: ... Check 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 while shaking harness Does voltage fluctuate NO 6 12 VDC is not present Replace speedometer NO 6 12 VDC is present but no fluctuation to 0 1 VDC Replace speedometer sensor YES Repair as necessary NO Check for spark plug ...

Page 402: ... Repair Open in Circuit Replace Speedometer Instrument Connector 20 Terminal Wire Color Indicator 1 Orange White Power 2 Brown Right Turn 3 White High Beam 4 Violet Left Turn 5 Tan Neutral 6 Green Yellow Oil Pressure 7 Black Right Left Turn High Beam 8 Not Used Not Used 9 Red Sensor Power 10 White Sensor Return 11 Black Sensor Ground 12 Not Used Not Used Replace Oil Pressure Switch Repair Open in ...

Page 403: ...ANK COVER FUEL TANK 5 Remove windscreen See 2 26 WINDSCREEN 6 Remove headlamp housing and disconnect connector 38 See 7 17 HEADLAMP 7 Note location of cable straps and cut three cable straps on frame backbone that secure main wiring harness to frame Disconnect harness from T studs 8 Disconnect speedometer connector 39 9 Disconnect right and left handlebar switch connectors 22 and 24 front brake sw...

Page 404: ... on right side of motorcycle 26 See Figure 7 95 Unplug flasher relay connector 30 and starter relay connector 123 located in frame tray on right hand side 27 Unplug system relay connector 171 located in frame tray on left side 28 See Figure 7 95 Disconnect positive wire from bat tery on circuit breaker upper stud 29 Disconnect tail lamp turn signal mini harness connector 7 located under seat 30 Un...

Page 405: ...raps to secure wires 7 See Figure 7 97 Mate speed sensor connector 65 Tuck excess harness into right frame pocket 8 Connect two blade terminals to stoplight switch above swingarm 9 Mate side stand switch connector 60 located above swingarm cable strap wires 10 Install starter connector 128 located under starter sole noid 11 Install neutral switch bullet connector 172 12 Install oil pressure switch...

Page 406: ...housing See 7 17 HEADLAMP 29 Install windscreen See 2 26 WINDSCREEN 30 Install fuel tank 4 2 FUEL TANK COVER FUEL TANK 11WARNING 1WARNING Always connect the positive battery cable first If the pos itive cable should contact ground with the negative cable installed the resulting sparks could cause a battery explosion which could result in serious injury or death 31 Install battery and reconnect bat...

Page 407: ...SUBJECT PAGE NO A 1 Tools A 1 B 1 Electrical Connectors B 1 B 2 Deutsch Electrical Connectors B 2 B 3 Amp Multilock Electrical Connectors B 4 C 1 Metric Conversion C 1 Table Of Contents APPENDICES ...

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