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2001 BUELL P3

SERVICE MANUAL

Part Number 99491-01Y


Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive/Transmission
Section 7: Electrical
Appendix
Table Of Contents
MAINTENANCE 1

SUBJECT PAGE NO.


1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.3 Body Panel Care/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6 Brake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7 Brakes Pads and Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.9 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.10 Transmission/Primary Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.11 Drive Belt and Rear Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.12 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.13 Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.14 Front Fork Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.15 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.16 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1.17 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.18 Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.19 Ignition Timing and Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.20 Fuel Supply Valve and Filter Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1.21 Starter Interlock and Electrical Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1.22 Critical Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.23 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
HOME

GENERAL 1.1

SERVICING A NEW MOTORCYCLE All special tools and torque v alues are noted at the point of
use.
All required parts or materials can be found in the appropriate
11
1WARNING
WARNING PARTS C ATALOG.

Always follow the listed service and maintenance recom- Safety


mendations, because the y aff ect the saf e operation of
the motorcycle and the personal welfare of the rider. Fail- Safety is always the most impor tant consideration when per-
ure to f ollow recommendations could result in death or forming any job. Be sure you have a complete understanding
serious injury. of the task to be perf ormed. Use common sense . Use the
proper tools. Protect y ourself and b ystanders with appro ved
Service operations to be performed before customer delivery eye protection14
are specified in the applica le model y ear PREDELIVER Y
AND SETUP MANUAL. . Dont just do the job do the job safely.
The performance of new motorcycle initial service is required Removing Parts
to keep warranty in force and to ensure proper emissions sys-
tems operation. Always consider the weight of a par t when lifting. Use a hoist
whenever necessary. Do not lift hea vy parts by hand. A hoist
After a ne w motorcycle has been dr iven its first 1000 mile
and adjustab le lifting beam or sling are needed to remo ve
(1600 km) and every service interval thereafter, have a Buell
some parts. The lengths of chains or cab les from the hoist to
dealer perform the service operations listed in Table 1-1.
the par t should be equal and par allel and should be posi-
tioned directly o ver the center of the par t. Be sure that no
SAFE OPERATING MAINTENANCE obstructions will interf ere with the lifting oper ation. Ne ver
leave a par t suspended in mid-air . Alw ays use b locking or
proper stands to support the part that has been hoisted.
CAUTION If a par t cannot be withdr awn, verify that all f astening hard-
ware has been detached. Check to see if any parts are in the
Do not attempt to retighten engine head bolts. way of the part being removed.
Retightening can cause engine damage.
When removing hoses, wiring or tubes, always tag each par t
During the initial 500 mile (800 km) break-in period, to ensure proper installation.
use only Harley-Davidson 20W50 engine oil. Failure
to use the recommended oil will result in impr oper Cleaning
break-in of the engine cylinders and piston rings.
If y ou intend to reuse par ts, f ollow good shop pr actice and
A careful check of cer tain equipment is necessar y after peri- thoroughly clean the par ts bef ore reassemb ly. K eep all dir t
ods of storage, and frequently betw een regular ser vice inter- out of par ts. Seals, filters and c vers are used in this v ehicle
vals, to determine if additional maintenance is required. to keep out environmental dirt and dust. These items must be
Check: kept in good condition to ensure satisfactory operation.
1. Tires for abrasions, cuts and correct pressure. Clean and inspect all par ts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
2. Drive belt for proper tension and condition.
cover all par ts with clean lint-free cloth, paper or other mate-
3. Brakes, steering and throttle for responsiveness. rial. Be sure the part is clean when it is installed.
4. Brake fluid l vel and condition. Hydr aulic lines and fit
Always clean around lines or covers before they are removed.
tings f or leaks . Also , chec k br ake pads and rotors f or
Plug, tape or cap holes and openings to k eep out dir t, dust
wear.
and debris.
5. Cables for fraying, crimping and free operation.
6. Engine oil and transmission fluid l vels. Disassembly and Assembly
7. Headlamp, passing lamp, tail lamp, brake lamp and tur n Always assemble or disassemb le one par t at a time . Do not
signal operation. work on tw o assemblies simultaneously. Be sure to mak e all
necessary adjustments . Rechec k y our w ork when finished
Be sure that everything is done.
SHOP PRACTICES
Operate the v ehicle to perf orm an y final che k or adjust-
ments. If all is correct, the v ehicle is ready to go bac k to the
Repair Notes customer.

NOTE Checking Torques on Fasteners with Lock


General maintenance practices are given in this section.
Patches/Loctite Threadlocker
Repair = Disassembly/Assembly.
To check the torque on a fastener that has a lock patch do the
Replace = Removal/Installation. following:

2001 Buell P3: Maintenance 1-1


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1. Set the torque wrench f or the lowest setting in the giv en Be sure that the chamf ered side of the bear ing always faces
torque range for the fastener. the shoulder (when bear ings installed against shoulders).
2. Attempt to tighten fastener to set torque. If fastener does Lubricate bear ings and all metal contact surf aces bef ore
not move and lo west setting is satisfied (torque wrenc pressing into place . Apply pressure only on the par t of the
clicks), then the proper torque has been maintained b y bearing that makes direct contact with the mating part.
the fastener. Always use the proper tools and fixtures or remo ving and
3. If the f astener does mo ve, remove the f astener, reapply installing bearings.
the appropriate type of LOCTITE THREADLOCKER and
Bearings do not usually need to be remo ved. Remove bear-
tighten the fastener to Service Manual specification
ings only if necessary.

REPAIR AND REPLACEMENT Bushings


PROCEDURES Do not remove a bushing unless damaged, excessively worn
or loose in its bore . Press out b ushings that m ust be
replaced.
Hardware and Threaded Parts When pressing or driving bushings, be sure to apply pressure
Install helical thread inser ts when inside threads in castings in line with the bushing bore. Use a bearing/bushing driver or
are stripped, damaged or not capab le of withstanding speci- a bar with a smooth, flat end Never use a hammer to dr ive
fied torqu . bushings.

Replace bolts, nuts, studs, washers, spacers and small com- Inspect the bushing and the mated par t for oil holes. Be sure
mon hardware if missing or in any way damaged. Clean up or all oil holes are properly aligned.
repair minor thread damage with a suitable tap or die.
Gaskets
Replace all damaged or missing lubrication fitting .
Always discard gaskets after removal. Replace with new gas-
Use Teflon pipe sealant on pipe fitting threa . kets. Never use the same gask et twice. Be sure that gask et
holes match up with holes in the mating part.
Wiring, Hoses and Lines
Replace hoses, clamps, electr ical wir ing, electr ical switches Lip Type Seals
or fuel lines if they do not meet specification . Lip seals are used to seal oil or g rease and are usually
installed with the sealing lip f acing the contained lubr icant.
Instruments and Gauges Seal or ientation, however, may vary under diff erent applica-
Replace brok en or def ective instr uments and gauges . tions.
Replace dials and glass that are so scr atched or discolored Seals should not be removed unless necessary. Only remove
that reading is difficult seals if is necessar y to gain access to other par ts or if seal
damage or wear dictates replacement.
Bearings
Leaking oil or g rease usually means that a seal is damaged.
Anti-friction bear ings m ust be handled in a special w ay. To
Replace leaking seals to prevent overheated bearings.
keep out dir t and abr asives, co ver the bear ings as soon as
they are removed from the package. Always discard seals after remo val and replace with new
seals. Do not use the same seal twice.
Wash bear ings in a non-flamma le cleaning solution. Knock
out packed lubricant by tapping the bearing against a wooden O-Rings (Preformed Packings)
block. Wash bearings again. Cover bearings with clean mate-
rial after setting them down to dry. Never use compressed air Always discard O-r ings after remo val. Replace with new O-
to dry bearings. rings. To prevent leaks, lubr icate the O-r ings before installa-
tion. Apply the same type of lubr icant as that being sealed.
Coat bearings with clean oil. Wrap bearings in clean paper.
Be sure that all gask et, O-ring and seal mating surf aces are
thoroughly clean before installation.

Gears
Always check gears for damaged or worn teeth.
Lubricate mating surfaces before pressing gears on shafts.

Shafts
If a shaft does not come out easily , check that all n uts, bolts
or retaining r ings have been remo ved. Check to see if other
parts are in the way before using force.
Shafts fitted to tapered splines should be ery tight. If shafts
are not tight, disassemb le and inspect tapered splines . Dis-
card par ts that are w orn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mat-
ing parts together tightly.

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Clean all rust from the machined surfaces of new parts. Wrenches
Part Replacement Never use an extension on a wrench handle.
If possib le, alw ays pull on a wrench handle and adjust
Always replace worn or damaged parts with new parts.
your stance to prevent a fall if something lets go.
Never cock a wrench.
CLEANING Never use a hammer on any wrench other than a STRIK-
ING FACE wrench.
Part Protection Discard any wrench with broken or battered points.
Never use a pipe wrench to bend, raise or lift a pipe.
Before cleaning, protect r ubber par ts (such as hoses , boots
and electr ical insulation) from cleaning solutions . Use a
grease-proof barr ier mater ial. Remo ve the r ubber par t if it
Pliers/cutters/prybars
cannot be properly protected. Plastic- or vin yl-covered pliers handles are not intended
to act as insulation; do not use on live electrical circuits.
Cleaning Process Do not use pliers or cutters f or cutting hardened wire
Any cleaning method ma y be used as long as it does not unless they were designed for that purpose.
result in par ts damage . Thorough cleaning is necessar y f or Always cut at right angles.
proper parts inspection. Strip rusted paint areas to bare metal
Do not use any prybar as a chisel, punch or hammer.
before repainting.

Rust or Corrosion Removal Hammers


Never str ike one hammer against a hardened object,
Remove rust and corrosion with a wire br ush, abrasive cloth,
such as another hammer.
sand blasting, vapor blasting or rust remover. Use buffing cro
cus cloth on highly polished parts that are rusted. Always grasp a hammer handle fi mly, close to the end.
Strike the object with the full face of the hammer.
Bearings
Never work with a hammer which has a loose head.
Remove shields and seals from bear ings bef ore cleaning. Discard hammer if face is chipped or mushroomed.
Clean bearings with permanent shields and seals in solution.
Wear approved eye protection when using striking tools.
Clean open bear ings by soaking them in a petroleum clean-
Protect bystanders with approved eye protection.
ing solution. Never use a solution that contains chlorine.
Let bearings air dry. Do not dry using compressed air. Do not Punches/chisels
spin bearings while they are drying.
Never use a punch or chisel with a chipped or m ush-
roomed end; dress m ushroomed chisels and punches
INSPECTING with a fil .
Hold a chisel or a punch with a tool holder if possible.
When using a chisel on a small piece , clamp the piece
Leak Dye
fi mly in a vise and chip toward the stationary jaw.
When using leak dye with the black light leak detector, add Wear approved eye protection when using these tools.
1/4 oz. (7.4 ml) of dy e for each 1 quar t (0.9 l) of fluid in th
system being checked. Protect bystanders with approved eye protection.

Screwdrivers
TOOL SAFETY Dont use a scre wdriver for pr ying, punching, chiseling,
scoring or scraping.

Air Tools Use the right type of screwdriver for the job; match the tip
to the fastener.
Always use appro ved e ye protection equipment when Dont interchange POZIDRIV , PHILLIPS or REED
performing any task using air-operated tools. AND PRINCE screwdrivers.
On all po wer tools, use only recommended accessor ies Screwdriver handles are not intended to act as insula-
with proper capacity ratings. tion; do not use on live electrical circuits.
Do not exceed air pressure ratings of any power tools. Dont use a scre wdriver with rounded edges because it
Bits should be placed against w ork surf ace bef ore air will slip redress with a fil .
hammers are operated.
Ratchets and Handles
Disconnect the air supply line to an air hammer bef ore
attaching a bit. Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace par ts individually; ratch-
Never point an air tool at yourself or another person.
ets should be reb uilt with the entire contents of ser vice
Protect bystanders with approved eye protection. kit.

2001 Buell P3: Maintenance 1-3


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Never hammer or put a pipe e xtension on a r atchet or
handle for added leverage.
Always suppor t the r atchet head when using soc ket
extensions, but do not put your hand on the head or y ou
may interfere with the action of its reversing mechanism.
When breaking loose a fastener, apply a small amount of
pressure as a test to be sure the r atchets gear wheel is
engaged with the pawl.

Sockets
Never use hand sockets on power or impact wrenches.
Select the right size socket for the job.
Never cock any wrench or socket.
Select only impact soc kets f or use with air or electr ic
impact wrenches.
Replace sockets showing cracks or wear.
Keep sockets clean.
Always use appro ved eye protection when using po wer
or impact sockets.

Storage Units
Dont open more than one loaded dr awer at a time .
Close each drawer before opening up another.
Close lids and loc k dr awers and doors bef ore mo ving
storage units.
Dont pull on a tool cabinet; push it in front of you.
Set the br akes on the loc king casters after the cabinet
has been rolled to your work.

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Table 1-1. REGULAR MAINTENANCE INTERVALS

1 1 1 1 2 2 2
ODOMETER READING 1 2 5 7 0 2 5 7 0 2 5
SERVICE OPERATIONS 0 5 0 5 0 5 0 5 0 5 0
(see chart code below) 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
mi mi mi mi mi mi mi mi mi mi mi

Change engine oil and filter (includes d aining crankcase breather hose) R I R I R I R I R I R
Inspect air cleaner and filter element, se vice as required I I
Change rear belt and rear sprocket R
Check clutch adjustment I I I I I I
Change transmission/primary chain case lubricant and clean drain plugSee R R R R R R
dealer
Check/adjust primary chain A A A A A A A A A A A
Inspect brake pad linings and discs for wear (front and rear) I I I I I I I I I I I
Change rear brake pads and rear brake pins R
Check brake fluid rese voir levels and condition I I I I I I
Check rear brake pedal operation I I I I I I
Inspect oil lines and brake system for leaks I I I I I I I I I I I
Lubricate front brake hand lever, throttle control cables, clutch control cables (and L L L L L
hand lever) and side stand
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 or leaks I I I I I I I I I I I
Clean fuel tank filter scree 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 connections I I I I I I I I I I I
Change spark plug R R
Check tire pressure and inspect tread I I I I I I I I I I I
Check wheel bearings*
Change front fork oil X
Check stabilizer links and engine mounts I I
Check tightness of all critical fasteners: hand controls, brake system, axle nuts, T T
front fork components, riser and handle bar fasteners.
Check rear shock absorber I I
Check ignition timing I I
Check engine idle speed I I I I I I I I I I I
Inspect exhaust system hardware; including muffler st ap I I
Road test X X X X X X X X X X X
* Whenever wheel is removed (tire change, fork fluid chang , etc.)

NOTE:
See Table 1-1. The following codes are for the REGULAR MAINTENANCE INTERVALS Table:
I - Inspect & if necessary correct, clean or replace.
A - Adjust.
R - Replace or change.
T - Tighten to proper torque
L - Lubricated with specified lub icant
X - Perform

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Table 1-2. REGULAR MAINTENANCE INTERVALS

1 1 1 1 2 2 2
ODOMETER READING 1 2 5 7 0 2 5 7 0 2 5
SERVICE OPERATIONS 0 5 0 5 0 5 0 5 0 5 0
(see chart code below) 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
mi mi mi mi mi mi mi mi mi mi mi

Change engine oil and filter (includes d aining crankcase breather hose) R I R I R I R I R I R
Inspect air cleaner and filter element, se vice as required I I
Change rear belt and rear sprocket R
Check clutch adjustment I I I I I I
Change transmission/primary chain case lubricant and clean drain plugSee R R R R R R
dealer
Check/adjust primary chain A A A A A A A A A A A
Inspect brake pad linings and discs for wear (front and rear) I I I I I I I I I I I
Change rear brake pads and rear brake pins R
Check brake fluid rese voir levels and condition I I I I I I
Check rear brake pedal operation I I I I I I
Inspect oil lines and brake system for leaks I I I I I I I I I I I
Lubricate front brake hand lever, throttle control cables, clutch control cables (and L L L L L
hand lever) and side stand
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 or leaks I I I I I I I I I I I
Clean fuel tank filter scree 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 connections I I I I I I I I I I I
Change spark plug R R
Check tire pressure and inspect tread I I I I I I I I I I I
Check wheel bearings*
Change front fork oil X
Check stabilizer links and engine mounts I I
Check tightness of all critical fasteners: hand controls, brake system, axle nuts, T T
front fork components, riser and handle bar fasteners.
Check rear shock absorber I I
Check ignition timing I I
Check engine idle speed I I I I I I I I I I I
Inspect exhaust system hardware; including muffler st ap I I
Road test X X X X X X X X X X X
* Whenever wheel is removed (tire change, fork fluid chang , etc.)

NOTE:
See Table 1-1. The following codes are for the REGULAR MAINTENANCE INTERVALS Table:
I - Inspect & if necessary correct, clean or replace.
A - Adjust.
R - Replace or change.
T - Tighten to proper torque
L - Lubricated with specified lub icant
X - Perform

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FLUID REQUIREMENTS 1.2

GENERAL BRAKE FLUID

United States System 11


1WARNING
WARNING
Unless otherwise specified, all fluid olume measurements D.O.T. 4 brake fluid can cause irritation of yes and skin,
in this Ser vice Man ual are e xpressed in United States and may be harmful if swallowed. If large amount of flui
(U.S.) units-of-measure. See below: is s wallowed, induce v omiting b y administering tw o
tablespoons of salt in a glass of warm water . Call a doc-
Pint (U.S.) = 16 fluid ounces ( .S.)
tor. In case of contact with skin or eyes, flush with plent
Quart (U.S.) = 2 pints (U.S.) = 32 fl oz. (U.S.) of water . Get medical attention f or e yes. KEEP BRAKE
FLUID OUT OF THE REA CH OF CHILDREN. F ailure to
Gallon (U.S.) = 4 quarts (U.S.) =128 fl oz. (U.S.)
comply could result in death or serious injury.
British Imperial System Use only D.O.T. 4 BRAKE FLUID (Part No. 99953-99Y).
Fluid v olume measurements in this Ser vice Man ual do not
include the British Imperial (Imp.) system equivalents. The fol- FRONT FORK OIL
lowing conversions exist in the British Imperial system:
Pint (Imp.) = 20 fluid ounces (Im .) Use only TYPE E FORK OIL (Part No. HD-99884-80).

Quart (Imp.) = 2 pints (Imp.)


Gallon (Imp.) = 4 quarts (Imp.)
ENGINE OIL
Although the same unit-of-measure ter minology as the U .S. Use the proper g rade of oil f or the lo west temper ature
system is used in the Br itish Imper ial (Imp .) system, the expected before the next oil change.
actual volume of each British Imperial unit-of-measure differs
from its U .S. counter part. The U.S. fluid ounce is larger tha If it is necessar y to add oil and Har ley-Davidson oil is not
the British Imperial fluid ounc . However, the U.S. pint, quar t available, use an oil cer tified or diesel engines . Acceptab le
and gallon are smaller than the Br itish Imper ial pint, quar t diesel engine oil designations include CE, CF, CF-4 and CG-
and gallon, respectiv ely. Should y ou need to con vert from 4. The pref erred viscosities f or the diesel engine oils , in
U.S. units to Br itish Imperial units (or vice v ersa), refer to the descending order, are 20W -50, 15W-40 and 10W -40. At the
following: first oppo tunity, see a Buell dealer to change bac k to 100
percent Harley-Davidson oil.
Fluid ounces (U.S.) x 1.042 = fluid ounces (Im .)
Pints (U.S.) x 0.833 = pints (Imp.)
Table 1-2. Recommended Oil Grades
Quarts (U.S.) x 0.833 = quarts (Imp.)
COLD
Gallons (U.S.) x 0.833 = gallons (Imp.) HARLEY-
LOWEST WEATHER
HARLEY-DAVID- DAVID-
VISCOSITY AMBIENT STARTS
Fluid ounces (Imp.) x 0.960 = fluid ounces ( .S.) SON TYPE SON RAT-
TEMP. BELOW
ING
50 F
Pints (Imp.) x 1.201 = pints (U.S.)
H.D. Below
Quarts (Imp.) x 1.201 = quarts (U.S.) SAE

Multi-Grade HD 360 40F Excellent


10W40
Gallons (Imp.) x 1.201 = gallons (U.S.) (4C)
H.D. Above
Metric System SAE
Multi-Grade HD 360 40F Good
20W50
(4C)
Fluid v olume measurements in this Ser vice Man ual include
the metric system equivalents. In the metric system, 1 liter (L) H.D. Above
SAE
= 1,000 milliliters (mL). Should you need to convert from U.S. Regular Heavy HD 360 60F Poor
50
units-of-measure to metr ic units-of-measure (or vice v ersa), (16C)
refer to the following: H.D. Above
SAE
Extra Heavy HD 360 80F Poor
Fluid ounces (U.S.) x 29.574 = milliliters 60
(27C)
Pints (U.S.) x 0.473 = liters
Quarts (U.S.) x 0.946 = liters
Gallons (U.S.) x 3.785 = liters PRIMARY DRIVE/TRANSMISSION
Milliliters x 0.0338 = fluid ounces ( .S.) FLUID
Liters x 2.114 = pints (U.S.)
Liters x 1.057 = quarts (U.S.) Use only SPOR T-TRANS FLUID (P art No . 98854-96 quar t
Liters x 0.264 = gallons (U.S.) size or Part No. 98855-96 gallon size).

2001 Buell P3: Maintenance 1-7


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BODY PANEL CARE/MAINTENANCE 1.3

GENERAL Washing
To wash molded-in-color panels follow the instructions below:
The purpose of this topic is to provide special care and main-
tenance instr uctions required f or the molded-in-color body Rinse surface with water.
panels that are standard on your Buell Blast P3 motorcycle. Wash with Harley Wash or Harley Sun Wash.
Molded-in-color surf aces look lik e painted surf aces, b ut are Rinse surface thoroughly with water.
not. The color pigment is mixed in with the mater ial when the
part is made , not applied o ver the surf ace. Molded-in-color Dry with a clean chamois or soft dry natural fiber cloth
panels require different maintenance than painted surfaces to
maintain their or iginal shine . Using methods that w ork on Cleaning Between Washings
painted surfaces may ruin the finish of molded-in-color pa ts. Untreated molded-in-color body panels sometimes ha ve a
static charge that attracts dust. Applying Harley Gloss or Har-
ley Glaze Polish and Sealant to molded-in-color surf aces will
CAUTION
eliminate this condition.
Use of abrasive pr oducts or po wered buffing equipmen To k eep a high gloss finish on molded-in-color panel
will cause permanent cosmetic dama ge to molded-in- between washings, follow the instructions below:
color body panels. Use only the recommended pr oducts
and tec hniques outlined in these instructions to a void Spray Har ley Gloss onto surf ace and wipe with a clean soft
damaging molded-in-color body panels. natural fiber cloth or Ha ley Softcloth.
NOTE
CAUTION Rain or water will remove Harley Gloss from body panels.

Do not use touch-up paint on molded-in-color panels. Reapply Har ley Gloss as descr ibed above to k eep surfaces
looking their best.

RECOMMENDED PRODUCTS Polishing


Polishing molded-in-color body panels results in g reater sur-
Products recommended for the proper care and maintenance face gloss and a protective coating.
of molded-in-color body panels are a vailable at y our Buell
dealer and are listed below: Apply Har ley Glaze Polish and Sealant e very six months or
as required to k eep molded-in-color panels protected and
Harley Wash (P art No . 99715-90) or Har ley Sun Wash looking their best.
(Part No. 94659-98).
Clean and dry surfaces to be polished (see Washing).
Harley Gloss (Part No. 94627-98).
Apply Har ley Glaz e P olish and Sealant to clean, slightly
Harley Glaze Polish and Sealant (Part No. 99701-84). dampened cloth or sponge and apply to surf ace with a light
Harley Swirl and Scratch Treatment (Part No. 94655-98) overlapping motion. Make sure to cover all areas.

Harley Softcloth (Part No. 94656-98) Let Harley Glaze Polish and Sealant dry to a haze and buff off
residue with a clean soft cloth or Harley Softcloth.

CARE AND MAINTENANCE Minor Scratch Removal


To remo ve minor scr atches from body panels f ollow the
instructions below.
Decals
To remove light surface scratches and rubs, use Harley Swirl
NOTE and Scratch Treatment as recommended.
The body panels on Blast P3 Models are shipped from the
Make sure Swir l and Scr atch Treatment is applied with a
factory untreated and ready for decal application.
moist cloth and by hand (not by machine).
If Personal F/X decals are to be applied to molded-in-color
After scratch or r ub has been repaired, polish surf ace lightly
body panels, they must be applied to the or iginal, untreated
with Harley Glaze.
surface for proper adhesion. If Harley Glaze Polish and Seal-
ant or similar product has been applied to the panels , the NOTE
decal will not adhere proper ly. Apply w ax and g rease Black body panels are more prone to suffer permanent cos-
remover, such as Dupont Prep-Sol, to treated panels to metic damage if attempts to remove scratches are overdone.
remove Harley Glaze prior to applying decals for best results.
Prep-Sol is available at most automotive aftermarket dealers. Major Scratches
Follow instr uctions on product f or proper usage . F ollow
There is no repair procedure for severely scratched surfaces.
instructions provided with decals for proper application. Prep-
Severely scratched body panels must be replaced.
Sol will not affect molded-in-color panels. If you are unsure of
how to use this product, see your Buell dealer.

1-8 2001 Buell P3: Maintenance


HOME

BATTERY 1.4

DISCONNECTION AND REMOVAL


a0250x7x
Bolts (2)
1. Remove seat. See 2.29 SEAT. 60-96 in-lbs
(6.8-10.9 Nm)
Bolt
11
1WARNING
WARNING
5-8 ft-lbs
(-) (7-11 Nm)
To protect against shock and accidental star t-up of vehi-
cle, disconnect the negative battery cable before proced-
ing. Inadequate saf ety precautions could result in death
or serious injury.

(+)
11
1WARNING
WARNING Pad Pads (4)

Always disconnect the negative cable fi st. If the positive


cable should contact gr ound with the negative cab le Boot
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black)


from battery negative (-) terminal. Figure 1-1. Battery Installation
3. Unthread bolt and remo ve batter y positiv e cab le (red)
from battery positive (+) terminal.
4. Remove battery from motorcycle.

INSTALLATION AND CONNECTION


1. Place the fully charged battery on the battery pad, termi-
nal side facing up.

CAUTION

Connect the cab les to the correct batter y terminals or


damage to the motorcycle electrical system will occur.

11
1WARNING
WARNING

Always connect the positive batter y cab le fi st. If the


positive cab le should contact gr ound with the negative
cable installed, the resulting sparks ma y cause a batter y
explosion which could result in death or serious injury.

CAUTION

Overtightening bolts can damage battery terminals.

2. See Figure 1-1. Insert bolt through battery positive cable


(red) into threaded hole of batter y positive (+) ter minal.
Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).
3. See Figure 1-1. Inser t bolt through batter y negativ e
cable (b lack) into threaded hole of batter y negativ e (-)
terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).
4. Apply a light coat of petroleum jelly or corrosion retar-
dant material to both battery terminals.
5. Install seat. See 2.29 SEAT.

1-9 2001 Buell P3: Maintenance


HOME

ENGINE LUBRICATION SYSTEM 1.5

GENERAL
CAUTION
Check engine oil level (hot check): Do not s witch engine oil brands indiscriminatel y. Some
At every stop for fuel. oils interact c hemically when mix ed. Use of inf erior oils
or non-detergent oils can damage the engine.
Inspect oil lines and filter or leaks:
The motorcycle should be r idden for approximately 10 min-
At 1,000 mi (1,600 km) initial ser vice and e very
utes to ensure oil is hot and engine is at nor mal oper ating
2,500 mi (4,000 km) service interval.
temperature.
Change engine oil and filter (and d ain cr ankcase breather
hose) under nor mal ser vice in w arm or moder ate temper a-
tures:
At 1,000 mi (1,600 km) initial ser vice and e very a0075xox Dipstick
5,000 mi (8,000 km) service interval thereafter.
Change engine oil and filter (and d ain cr ankcase breather
hose) under se vere ser vice in w arm or moder ate temper a-
tures (severe dust, temperatures above 80oF/27oC, extensive
idling or speeds in e xcess of 65 mph/105 km/h, e xtensive
two-up riding):
At 1,000 mi (1,600 km) initial ser vice and e very
2,500 mi (4,000 km) service interval thereafter.
NOTE
Shorten oil change interval in cold weather.
Filler hole

CHECKING ENGINE OIL LEVEL


An accur ate engine oil le vel reading can only be obtained a0016xox Correct Hot Oil Level
with the engine is at nor mal oper ating temper ature (Hot (Between Arrows)
Check). The engine will require a longer w arm up per iod in
colder weather.
For pre-r ide inspection, simply v erify that there are no oil
leaks from the oil filter and oil lines p ior to oper ating the
motorcycle.
Perform a hot chec k of the engine oil le vel at each fuel
stop. Figure 1-2. Dipstick Location/Engine Oil Level
Hot Check
1. The motorcycle must be in upright position and level (not
on sidestand) with the engine OFF.
CAUTION 2. See Figure 1-2. Unscrew dipstick from frame filler hol .
Do not allow hot oil level to fall below lower mark on dip- 3. Wipe off dipstic k and inser t into fr ame filler hol , screw-
stick. To do so ma y result in equipment dama ge and/or ing dipstick completely into filler ne k.
equipment malfunction. 4. See Figure 1-2. Remove dipstick and note oil level.
5. Hot oil level should be between the upper and lower fill
CAUTION marks on dipstic k. If oil le vel is do wn to or belo w lower
Do not o verfill oil tank Doing so ma y result in oil carr y- fill mark on dipstic k, add only enough oil to br ing level
over to the air c leaner, equipment dama ge and/or equip- between lower and upper fill marks.
ment malfunction.

Table 1-3. Recommended Engine Oils


Harley-Davidson Harley-Davidson Lowest Ambient
Viscosity Cold Weather Starts Below 50F (10C)
Type Rating Temperature
HD Multi-grade SAE 10W40 HD 360 Below 40F (4C) Excellent
HD Multi-grade SAE 20W50 HD 360 Above 40F (4C) Good
HD Regular Heavy SAE 50 HD 360 Above 60F (16C) Poor
HD Extra Heavy SAE 60 HD 360 Above 80F (27C) Poor

2001 Buell P3: Maintenance 1-10


HOME

CHANGING ENGINE
OIL AND FILTER a0074xox

3
2
4
CAUTION

Do not s witch oil brands indiscriminatel y; some oils


interact c hemically when mix ed. Use of inf erior oils or 5
non-detergent oils can damage the engine.
1. See Figure 1-3. Locate the engine oil tank dr ain hose
(normally the lo wer hose) and the cr ankcase breather
drain hose (normally the upper hose) inside the f oot peg
support frame on the left side of the motorcycle.
2. Remove fastener from hose retention clamp. 1
3. Place a dr ain pan directly under neath the engine oil
drain hose.
1. Hose Retention Clamp Fastener
4. Loosen the spr ing clamp and remo ve engine oil dr ain 2. Oil Tank Drain Hose (lower hose) Crankcase
drain plug from drain hose. Breather Hose (upper hose)
5. Allow used oil to drain completely. 3. Spring Clamp
4. Engine Oil Drain Hose Cap
6. Loosen spr ing clamp and remo ve cr ankcase breather 5. Foot peg Support Frame
hose drain plug to allow any oil present to drain.
7. See Figure 1-4. Remove the oil filter (located at the fron Figure 1-3. Oil Tank Drain Hose
of the engine).
8. Clean filter gas et contact surf ace on mounting plate
a0019xox
(surface should be smooth and free of an y debris, used
oil or old gasket material).
Apply thin film of clean
9. See Figure 1-4. Apply a thin film of clean oil to gas et on engine oil to gasket
new oil filte .
10. Install new oil filter ( art No . 63806-00Y) onto adapter
until gasket contacts plate surf ace, then tighten another
1/2 to 3/4 turn. Do not overtighten.
a0073xox
11. Place tw o dr ain hoses bac k on the hose fixtur . Install
drain plugs to dr ain hoses and secure plugs with spr ing
clamps.
12. See Figure 1-2. See Table 1-3. Remove dipstick and refil
with approximately 1.5 qts (1,419.5 ml) recommended oil
at filler hol . Filter
Mount
13. Install dipstick and operate motorcycle for 10 minutes to
reach nor mal oper ating temper ature. Chec k oil le vel
again (hot check) and add oil as necessary until oil regis-
ters between marks on dipstick.
Tighten Oil Filter 1/2 to 3/4
turn after Gasket Contact
11
1WARNING
WARNING
Figure 1-4. Installing New Oil Filter
Make sure no oil g ets on tires when c hanging oil and fil
ter. Failure to comply may adversely affect traction which
could lead to a loss of control which could result in death
or serious injury.

Change oil more frequently if bike is operated under


severe conditions (dusty, very hot or cold temperatures).
Drain oil after oper ating motorcycle (while oil is still v ery
warm).
Replace oil filter very time the oil is changed.
Drain the crankcase breather drain hose of any accumu-
lated oil every time the oil is changed.

2001 Buell P3: Maintenance 1-11


HOME

BRAKE SYSTEM MAINTENANCE 1.6

GENERAL 7703

Check the master cylinder reser voirs f or proper fluid l vels


after the first 1000 miles (1600 km) and very 5000 miles
(8000 km) thereafter. Also inspect fluid l vels at the end of
every riding season.

Check brake pads and rotors f or wear at every service inter-


val. See 1.7 BRAKE PADS AND ROTORS.

Inspect front and rear brake fluid l vel and condition:

At 1,000 mile (1600 km) initial ser vice and at e very


5,000 mile (8,000 km) service thereafter.

Replace D.O.T. 4 BRAKE FLUID:

Every 2 years.
Figure 1-5. Rear Brake Fluid Reservoir
Inspect front and rear brake system fitting and lines or leaks:

At 1,000 mile (1600 km) initial ser vice and at e very


7697
service thereafter. 6422

It is recommended to inspect both front and rear br ake lines


and replace as required: Bleeder Valve

Every 4 years.

It is recommended to inspect both front and rear caliper and


master cylinder seals and replace as required:

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 there-
after.
Lubricate the front brake hand lever: Figure 1-6. Front Brake Caliper Bleeder Valve

Every 5,000 miles (8,000 km)

FLUID LEVEL 7723

Bleeder Valve
See Figure 1-5. With motorcycle in a level position, check that
(metric)
brake fluid is bet een the upper and lo wer mar ks on front
and rear reser voirs. Add D.O.T. 4 BRAKE FLUID if neces-
sary. Be sure gasket and cap on reservoir fit securel .

BLEEDING BRAKES

11
1WARNING
WARNING

D.O.T. 4 brake fluid can cause irritation of yes and skin,


and may be harmful if swallowed. If large amount of flui
is s wallowed, induce v omiting b y administering tw o
tablespoons of salt in a glass of warm water . Call a doc- Figure 1-7. Rear Brake Caliper Bleeder Valve (Metric)
tor. In case of contact with skin or eyes, flush with plent
of water . Get medical attention f or e yes. KEEP BRAKE
FLUID OUT OF THE REA CH OF CHILDREN. F ailure to
comply could result in death or serious injury.
.

2001 Buell P3: Maintenance 1-12


HOME
7. Verify master cylinder fluid l vel as described in Step 2.
11
1WARNING
WARNING

Never mix D.O.T. 4 with other brake fluids (su h as D.O.T. 11


1WARNING
WARNING
5). Use only D.O.T. 4 brake fluid in moto cycles that spec- Always test motorcycle brakes at low speed after ser vic-
ify D .O.T. 4 fluid on the rese voir cap. Mixing diff erent ing or bleeding system. If brakes are not operating pr op-
types of fluid m y ad versely aff ect braking ability and erly, or braking efficien y is poor, testing at high speeds
lead to brake failure whic h could result in death or seri- could result in death or serious injury.
ous injury

11
1WARNING
WARNING a0214x2x

Use onl y fresh, uncontaminated D .O.T. 4 Fluid. Cans of Brake fluid level
fluid that h ve been opened ma y ha ve been contami-
nated by moisture in the air or dir t. Use of contaminated
brake fluid m y adversely affect braking ability and lead
to brake failure whic h could result in death or serious
injury

11
1WARNING
WARNING

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 compatib le with D .O.T. 4 fluid and wil
not seal pr operly o ver time . F ailure to compl y ma y
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
NOTE
Hydraulic brake fluid bladder-type pressure equipment can
be used to fill the brake master cylinder through the bleeder Figure 1-8. Brake Fluid Level - Front Reservoir
valve if master cylinder reservoir cover is removed to prevent
pressurization. 8. Attach covers to master cylinder reservoirs.
1. Install end of a length of plastic tubing o ver caliper a. Tighten screws on master cylinder reservoir cover to
bleeder v alve; place other end in a clean container . 9-13 in-lbs (1.0-1.5 Nm).
Stand motorcycle upright. b. Tighten cap on rear master cylinder securely.
a. See Figure 1-6. Front brake bleeder valve.
b. See Figure 1-7. Rear brake bleeder valve.
REAR BRAKE PEDAL
CAUTION

Cover molded-in-color surfaces and right handlebar 11


1WARNING
WARNING
switches and use care when remo ving brake reser voir Always test motorcycle brakes at low speed after ser vic-
cover and ad ding D .O.T. 4 brake fluid Spilling D .O.T. 4 ing or bleeding system. If brakes are not operating pr op-
brake fluid on molded-in-color surfaces will result in cos erly, or braking efficien y is poor, testing at high speeds
metic damage. Spilling brake fluid on witches may ren- could result in death or serious injury.
der them inoperative.
Check rear brake pedal for proper operation.
2. Add D.O.T. 4 BRAKE FLUID to master cylinder reser-
voir. Do not reuse brake fluid Before every ride.
a. Remove two screws from front master cylinder cover. At the 1000 mile (1600 km) ser vice inter val and at
Bring fluid l vel to within 0.125 in. (3.2 mm) of every 5000 mile (8000 km) ser vice interval thereaf-
molded boss inside front master cylinder. ter.
b. Remove cap and gask et from rear master cylinder 1. Inspect locknut installation. Locknut should be flush wit
reservoir. Br ing fluid l vel to betw een upper and top surface of clevis.
lower marks on reservoir. 2. Observe the position of br ake pedal and foot peg. Brake
3. Depress, release and then hold brake lever/pedal to build pedal should be set so top surface of brake pedal is even
up hydraulic pressure. with top surface of foot peg.
4. Open bleeder valve (metric) about 1/2-turn counterclock- 3. Set brake pedal height.
wise; brake fluid will f w from bleeder valve and through a. Loosen locknut.
tubing. When brake lever/pedal has moved 1/2-3/4 of its
b. Turn rod adjuster to obtain correct position.
full range of travel, close bleeder valve (clockwise). Allow
brake lever/pedal to return slowly to its released position. c. Tighten locknut.
5. Repeat Steps 2-4 until all air bubbles are purged. NOTE
6. Tighten bleeder valve (metric) to 3-5 ft-lbs (4.1-6.8 Nm). Brake pedal has no freeplay adjustment.
2001 Buell P3: Maintenance 1-13
HOME

BRAKE PADS AND ROTORS 1.7

BRAKE PADS a0031xox Metal Backing


Plate

11
1WARNING
WARNING Friction
Material
Always replace brake pads in complete sets f or 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.

Check front and rear brake pads for minimum thickness:

At the 1000 mile (1600 km) service interval.


At every scheduled service interval thereafter.

See Figure 1-9. See Figure 1-10. Inspect br ake pads f or 1/16 in. (1.6 mm)
damage or excessive wear. Replace both pads as a set if fric- Minimum
tion material of either pad is worn to 0.04 in. (1.0 mm) or less.
If this amount of wear occurs, wear grooves (2) will disappear
Figure 1-9. Brake Pad - Side View
from friction material surface.

Replace rear brake pads and pins: a0025xox

Every 15,000 miles (24,000 km)

NOTE

Always replace brake pads in pairs. Brake Pad

BRAKE ROTORS Disc

11
1WARNING
WARNING

Do not allo w brake fluid bearing grease or other lubri- Figure 1-10. Measuring Rear Brake Outer Pad
cants to contact brake r otor 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 thic kness. Replace if minim um thickness
is less than 0.18 in. (4.5 mm).

2. Check rotor surface. Replace if warped or badly scored.

3. The br ake rotor m ust be within the f ollowing specifica


tions. If the br ake rotor is suspected of being damaged,
inspect rotor using the following measurements:

Lateral Movement: 0.01-0.02 in. (0.3-0.5 mm)


Radial Movement: 0.02 in. (0.45 mm)
Rotational Movement: 0.02 in. (0.39 mm)

2001 Buell P3: Maintenance 1-14


HOME

TIRES AND WHEELS 1.8

TIRE INFLATION
1-4. Tire Specifications/Pressure
Check front and rear tires f or proper inflation and inspec
SOLO LOADED
tread for cuts or punctures: P3 Tires
RIDING TO GVWR
Weekly, and at 1,000 mile (1,600 km) initial ser vice
Front 28 psi 32 psi
and at e very 2,500 mile (4,000 km) ser vice inter val
Dunlop 100/80 16 50s K330 (193 kPa) (220 kPa)
thereafter.
Rear 30 psi 36 psi
Dunlop 120/80 16 60s K330 (207 kPa) (248 kPa)
WHEEL BEARINGS
The wheel bear ings are sealed units , no greasing or mainte-
nance is required. Replace when w orn. Excessiv e pla y or
roughness indicates worn bearings that require replacement.
Check wheel bearings:
Whenever wheel is remo ved (tire change , f ork oil
change).

1-15 2001 Buell P3: Maintenance


HOME

CLUTCH 1.9

GENERAL 11. Install left f ootpeg suppor t br acket. See 2.22 FOO T-
PEGS AND FOOTPEG SUPPORT BRACKETS.
Check clutch for proper adjustment:
At the 1,000 mile (1,600 km) initial ser vice and at
every 5,000 mile (8,000 km) service interval thereaf-
a0159x6x
ter.
Oil and adjust the clutch control cable: Rubber Boot
Every 5,000 miles (8,000 km) with LUBIT -8 TUFOIL
CHAIN AND CABLE LUBE (Part No. 94968-85TV). Cable End

ADJUSTMENT Jam Nut

Clutch control cab le adjustment is required at this inter val to


compensate for nor mal clutch lining w ear. If the clutch slips
under load, or drags when released, adjust the clutch control Adjuster
cable.
1. Raise rear wheel off floor using REAR WHEEL SUP-
PORT STAND (Part No. B-41174).
Figure 1-11. Clutch Cable Adjuster Mechanism
2. Remove left f ootpeg suppor t br acket. See 2.22 FOO T-
PEGS AND FOOTPEG SUPPORT BRACKETS.
3. See Figure 1-11. Slide rubber boot (1) upward to expose
a0155x6x
adjuster mechanism. Loosen jam n ut (3) from adjuster
(4). Turn adjuster to shorten cable housing until there is a
large amount of freeplay at clutch hand lever.
4. See Figure 1-12. Remo ve three TORX scre ws with
washers (1) from clutch inspection co ver (2). Remo ve
5
clutch inspection cover from primary cover. 4
3
NOTE 2
Quad ring removed from primary cover for illustrative pur- 1
poses only in Figure 1-12.
5. Remove spr ing (4) and loc kplate (5). Turn adjusting 6
screw (6) counterclockwise until it lightly bottoms.
6. Turn adjusting scre w (6) cloc kwise 1/4 tur n. Install loc k-
1. TORX Screw
plate (5) and spring (4) on adjusting screw flat . If hex on
2. Clutch Inspection Cover
lockplate does not align with recess in outer ramp, rotate
3. Quad Ring
adjusting screw clockwise until it aligns.
4. Spring
7. Squeeze clutch hand lever to maximum limit three times. 5. Lockplate
This sets the ball and r amp mechanism. Pull outer cable 6. Adjusting Screw
conduit and at the same time adjust cab le adjuster to
provide 0.0625-0.125 in. (1.6-3.2 mm) freepla y at clutch Figure 1-12. Clutch Release Mechanism
hand lever. Adjust as follows.
a. S ee Figure 1-13. Pull ferrule (end of cab le housing)
away from bracket. Gap between ferrule and bracket
should be 0.0625-0.125 in. (1.6-3.2 mm). a0158x6x

b. See Figure 1-11. Set freeplay by turning adjuster. Bracket


Ferrule
c. Tighten jam nut against adjuster.
0.0625-0.125 in.
d. Slide rubber boot over cable adjuster mechanism. (1.6-3.2 mm)
8. Change or add transmission fluid if necessa y.
NOTE
Clean parts before re-assembly and use a new gasket.
9. See Figure 1-12. Install clutch inspection co ver using
three TORX screws with washers. Tighten in a crosswise
pattern to 7-9 ft-lbs (9.5-12.2 Nm).
10. Check clutch cable freeplay. See Step 6 above. Figure 1-13. Adjusting Clutch Freeplay

2001 Buell P3: Maintenance 1-16


HOME

TRANSMISSION/PRIMARY FLUID 1.10

GENERAL 7667
1
The tr ansmission should be dr ained and refilled with fres
fluid

At the 1,000 mile (1,600 km) initial ser vice and at


every 5,000 (8,000 km) service interval thereafter.
Transmission fluid capacity is 1.0 qua t (0.95 liter). For best
results, drain fluid while it is hot

INSPECTION
1. Remove seat. See 2.29 SEAT. 2 3

11
1WARNING
WARNING

To protect against shock and accidental star t-up of vehi- 1. Torx Screws with washers (3)
cle, disconnect the negative batter y cab le bef ore pr o- 2. Clutch Inspection Cover
ceeding. Inadequate saf ety precautions could result in 3. Magnetic Drain Plug (with O-ring)
death or serious injury.

2. Disconnect negative battery cable from battery. Figure 1-14. Primary Cover

3. Remove left f ootpeg suppor t br acket. See 2.22 FOO T-


PEGS AND FOOTPEG SUPPORT BRACKETS. a0126x6x

4. Remove three TORX scre ws with w ashers (1) from


clutch inspection co ver (2). Remo ve clutch inspection
cover from primary cover.
5. See Figure 1-15. Inspect fluid l vel with motorcycle in
upright position. 1
6. See Figure 1-14. Install clutch inspection co ver using
three TORX screws with washers. Tighten in a crosswise
pattern to 7-9 ft-lbs (9.5-12.2 Nm).
3
7. Install left f ootpeg suppor t br acket. See 2.22 FOO T-
PEGS AND FOOTPEG SUPPORT BRACKETS. 4
8. Connect negative batter y cable to batter y. See 1.4 BAT-
TERY.
9. Install seat. See 2.29 SEAT.
2
CHANGING TRANSMISSION FLUID 1. Adjusting Screw
2. Cable End
3. Coupling
1. Raise rear wheel off floor using REAR WHEEL SUP- 4. Correct Fluid Level
PORT STAND (Part No. B-41174). This pre vents tr ans-
mission fluid from spilling out of the clutch inspectio Figure 1-15. Fluid Level
cover opening.
2. See Figure 1-14. P osition a suitab le container under
drain plug (3). Remove magnetic dr ain plug with O-r ing
and drain fluid
3. Wipe any foreign mater ial from the magnetic dr ain plug
(3). Inspect O-r ing f or deter ioration and replace as
required. Reinstall dr ain plug with O-r ing. Tighten dr ain
plug to 14-30 ft-lbs (19.0-54 Nm).
4. Remove seat. See 2.29 SEAT.

1-17 2001 Buell P3: Maintenance


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