2

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SPECIFICATIONS
DIMENSIONS Wheel Base Seat Height - Low Seat High Seat Road Clearance Trail Rake IN. 55.30 25.50 27.50 5.10 3.4 25 MM 1404 648 698 129.5 86 TRANSMISSION GEAR RATIOS First (low) Gear WEIGHT-U.S. MODELS Wet Weight GVWR GAWR Front GAWR Rear Load Capacity LBS. 380 780 280 500 400 KG 172 353 127 226 181 Second Gear Third Gear Fourth Gear Fifth (high) Gear FINAL* 2.69 1.85 1.43 1.18 1.00 Spark Plug Size Gap Torque IGNITION SYSTEM 10R12 12 mm 0.038-0.043 in. 11-18 ft-lbs

2.1

0.97-1.09 mm 15-24.4 Nm OVERALL** 12.74 8.77 6.79 5.60 4.74

*Final gear ratios indicate number of mainshaft revolutions required to drive output sprocket one revolution. **Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution.

NOTE See information decal on frame steering head for Gross Vehicle Weight Rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR).

SPROCKET TEETH Engine Clutch 35 56 27 80

CAPACITIES Fuel Tank: Total (including reserve) Reserve Oil Tank (with filter) Transmission/Primary Front Fork (each-wet capacity)

U.S.

Metric

Transmission Rear Wheel

2.8 gallons 0.55 gallons 2.0 quarts 32.0 ounces 9.2 ounces

10.60 liters 2.08 liters 1.89 liters

ENGINE 946.35 ml 272.08 ml Number of Cylinders Type 1 4-Cycle, Air cooled, four stroke 3.5 in. 3.125 in. 30 cu. in. 9.2:1 30 @ 6500 27 @ 3200 OHV, two valves Hydraulic, self-adjusting lifters 40mm Keihin CV carburetor 88.9 mm 79.375 mm 492 cc

11WARNING 1WARNING
Do not inate any tire beyond its maximum ination pressure as specied on tire sidewall. Overination may lead to premature tire failure which could result in death or serious injury.

Bore Stroke Engine Displacement Compression Ratio Horsepower @ RPM Torque ft-lbs @ RPM

TIRE AND POSITION Front Dunlop 100/80 16 50s K330 Rear Dunlop 120/80 16 60s K330

SOLO RIDING 28 PSI (193 kPa) 30 PSI (207 kPa)

LOADED TO GVWR 32 PSI (220 kPa) 36 PSI (248 kPa)

Valve Train Valve Adjustment Fuel Delivery

Gasoline
Use a good quality unleaded gasoline which is 87 pump octane or higher (R+M)/2. Octane rating is usually found on the pump. 2002 Buell P3: Chassis 2-1

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TORQUE VALUES

ITEM Brake bleeder valve Clutch lever screw Footpeg support mounting bracket bolts Frame-to-isolator rear fastener 3-5 ft-lbs

TORQUE 4-7 Nm 6-7 Nm 34-41 Nm 41-45 Nm

NOTES Metric, Page 2-19 Page 2-63 Page 2-53 Apply several drops of LOCTITE thread locker 272 (red) to last few threads, Page 2-65 Tighten in criss-cross pattern. Apply several drops of LOCTITE thread locker 272 (red) to last few threads, Page 2-11 Apply several drops of LOCTITE thread locker 243 (blue) to last few threads. Metric, Page 2-9 Metric, Page 2-9 Apply several drops of LOCTITE thread locker 272 (red) to last few threads, Page 2-25 Metric, Page 2-25 Metric, Page 2-21 LOCTITE ANTI-SEIZE, Page 2-21 Page 2-26 Page 2-21 Page 2-55 Torque to 20 ft-lbs (27.1 Nm), turn bolt clockwise an additional 63-67, Page 264 Page 2-52 Page 2-54 Page 2-64 Page 2-63 Page 2-63 Apply several drops of LOCTITE thread locker 243 (blue) to last few threads, metric, Page 2-60 Lower rst, Page 2-52 Page 2-56 Page 2-25 Page 2-64 Page 2-50 Metric, Page 2-31 Metric, Page 2-31

50-60 in-lbs 25-30 ft-lbs 30-33 ft-lbs

Front and rear brake rotor screws, TORX

24-27 ft-lbs

33-37 Nm

Front axle nut Front axle pinch screw Front brake caliper mounting bolts Front brake caliper pad hanger pin Front brake hand lever nut Front brake hand lever pivot bolt Front brake line clamp screw Front brake switch screw Front fender mounting screws Front isolator mount bolt Front mufer bolts Front sprocket cover bolts Front tie bar bolt Handlebar clamp fasteners Handlebar left and right housing screws Instrument panel screws Lower and upper header nuts Lower belt guard Master cylinder cover screws Outboard isolator bolts Rear axle nut Rear brake caliper mounting screw, large Rear brake caliper mounting screw, small 2-2 2002 Buell P3: Chassis

38-42 ft-lbs 13-16 ft-lbs 18-22 ft-bs 11-15 ft-lbs 44-62 in-lbs 4-13 in-lbs 3-5 ft-lbs 7-13 in-lbs 27-30 in-lbs See NOTES 22-25 ft lbs 30-36 in-lbs 30-33 ft-lbs 10-12 ft-lbs 25-33 in-lbs 30-36 in-lbs 6-8 ft-lbs 30-36 in-lbs 9-13 in-lbs 30-33 ft-lbs 48-52 ft-lbs 18-22 ft-lbs 15-18 ft-lbs

52-57 Nm 18-22 Nm 24-30 Nm 15-20 Nm 5-7 Nm 0.5-1.5 Nm 4-7 Nm 0.8-1.5 Nm 3.1-3.4 Nm See NOTES 30-34 Nm 3-4 Nm 41-45 Nm 14-16 Nm 3-4 Nm 3-4 Nm 8-11 Nm 3-4 Nm 1.0-1.5 Nm 41-45 Nm 65-71 Nm 24-30 Nm 20-24 Nm

HOME ITEM Rear brake caliper pad hanger pin Rear brake fastener Rear brake reservoir mounting screw Rear drive sprocket bolts Rear fender mounting screws Rear isolator-to engine crankcase TORQUE 11-15 ft-lbs 6-8 ft-lbs 12-15 in-lbs 18-22 +40 ft-lbs 30-36 in-lbs 32-34 ft-lbs 15-20 Nm 8-11 Nm 1.4-1.7 Nm 24-30 Nm +40 3-4 Nm 46-50 Nm NOTES Metric, Page 2-31 Page 2-54 Page 2-28 Apply several drops of LOCTITE thread locker 272 (red) to last few threads. Page 2-11 Page 2-55 Apply several drops of LOCTITE thread locker 243 (blue) to last few threads, Page 2-65 Apply several drops of LOCTITE thread locker 243 (blue) to last few threads, metric, Page 2-28 Page 2-52 Page 2-33 Page 2-49 Page 2-49 Page 2-49 LOCTITE ANTI-SEIZE, Page 2-47 Apply anti-seize to bolt and install, Page 2-50 Apply several drops of LOCTITE thread locker 243 (blue) to last few threads, Page 2-50 Metric, Page 2-34 Page 2-17 Page 2-59

Rear master cylinder mounting screws Rear mufer strap bolts Rear shock top and bottom bolt Steering head cap nut pinch screw Steering head cap nut Steering head lower triple tree clamp screws Steering head upper triple tree clamp screws (at sliders) Swingarm bolt

4-6 ft-lbs 22-25 ft lbs 35-40 ft-lbs 7-10 ft-lbs 28-32 ft-lbs 22-29 ft-lbs 13-16 ft-lbs 24-26 ft-lbs

5-8 Nm 30-34 Nm 47-54 Nm 10-14 Nm 38-43 Nm 30-39 Nm 18-22 Nm 33-35 Nm

Swingarm pinch bolt Switchgear housing screws, right side Valve stem nut Windscreen screws

17-19 ft-lbs 12-17 in-lbs 42-44 in-lbs 9-11 in-lbs

23-26 Nm 1-2 Nm 4.7-5.0 Nm 1 Nm

2002 Buell P3: Chassis

2-3

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TIRE SPECIFICATIONS
GENERAL 11WARNING 1WARNING
Tires must be correctly matched to wheel rims. Only the tires listed in the tment table below can be used for replacement. Mismatching tires and rims can cause damage to the tire bead during mounting. Using tires other than those specied can adversely affect motorcycle handling which could result in death or serious injury.

2.2
Tire sizes are molded on the sidewall. Rim size and contour are marked on the rims 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, measured at the bead seat diameter. DOT means that the rim meets Department of Transportation Federal Motor Vehicle Safety Standards.

See the table below.

Table 2-1. Tire Fitment-Tubeless Cast Wheels

WHEEL SIZE & POSITION 16 in. Front 16 in. Rear CONTOUR & RIM SIZE MT 2.5 x 16.0 DOT MT 2.75 x 16.0 DOT RIM VALVE HOLE DIAMETER 0.33 in. (8.38 mm) 0.33 in. (8.38 mm) DUNLOP RADIAL TIRE SIZE 100/80 16 K330 120/80 16 K330

2-4

2002 Buell P3: Chassis

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VEHICLE IDENTIFICATION NUMBER

GENERAL
See Figure 2-1. Each vehicle has a 17-digit serial or Vehicle Identification Number (V.I.N.) stamped on the steering head. A Motor Identification Number is stamped on the left side crankcase near the front of the engine.

2.3

NOTE Always give the full 17-digit Vehicle Identication Number when ordering parts or making inquiries about your Buell motorcycle.

Manufacturer: Buell Motorcycle Company Type Designation: Buell Blast P3 Engine 13 =World 58 =California

Horsepower Code Check Digit* Model Year 2002 3 - Manufactured in East Troy, WI Sequential Number 500001-520000 = World 520001-525000 = CA

MZ

KP

13

500015

**Varies - can be 0-9 or X

Sample V.I.N. as it appears on the steering head - 4MZKP13C723500015 Sample abbreviated V.I.N. as it appears on the left side crankcase - KP132500015 Figure 2-1. Vehicle Identication Numbers (V.I.N.)

2002 Buell P3: Chassis

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WHEELS
GENERAL
Good handling and maximum tire mileage are directly related to the care of wheels and tires. Regularly inspect wheels and tires for damage and wear. If handling problems occur, see Table 2-2. Keep tires inated to the recommended air pressure. Always balance the wheel after replacing a tire.
a0198x2x

2.4

11WARNING 1WARNING
Do not inate any tire beyond its maximum ination pressure as specied on tire sidewall. Overination may lead to premature tire failure which could result in death or serious injury.

TROUBLESHOOTING
See Figure 2-2. Check tire ination pressure at least once each week. At the same time, inspect tire tread for punctures, cuts, breaks and other damage. Repeat the inspection before long trips.

Figure 2-2. Checking Tire Ination Pressure

Table 2-2. Wheel Service

CHECK FOR Loose axle nuts. REMEDY Apply LOCTITE THREADLOCKER 243 (Blue) and tighten front axle nut (metric) to 38-42 ft-lbs (52-57 Nm). Tighten rear axle nut (metric) to 48-52 ft-lbs (65-71 Nm). Replace wheel hub bearings. Repair swingarm as described under 2.19 SWINGARM. Replace rims. See 2.9 TIRES. Replace rims. See 2.9 TIRES.

Excessive side-play or radial (up-and-down) play in wheel hubs. Alignment of rear wheel in frame or with front wheel. Rims and tires out-of-true sideways; should not be more than 0.080 in. (2.03 mm). Rims and tires out-of-round or eccentric with hub; should not be more than 0.090 in. (2.29 mm). Irregular or peaked front tire wear. Correct tire ination. Correct tire and wheel balance. Steering head bearings. Damper tubes. Shock absorber. Swingarm bearings.

Replace as described under 2.5 FRONT WHEEL or 2.9 TIRES. Inate tires to correct pressure. See 2.2 TIRE SPECIFICATIONS. Static balance may be satisfactory if dynamic balancing facilities are not available. However, dynamic balancing is strongly recommended. Correct adjustment and replace pitted or worn bearings. See 2.18 FORK STEM AND BRACKET ASSEMBLY. Check for leaks. See 2.17 FRONT FORK. Check damping action and mounts. See 2.15 REAR SHOCK ABSORBER. Check for looseness. See 2.19 SWINGARM.

2-6

2002 Buell P3: Chassis

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11WARNING 1WARNING
Use the following guidelines when installing a new tire or repairing a at. Failure to comply with the guidelines below could result in death or serious injury. 1. 2. Always locate and eliminate the cause of the original tire failure. Do not patch or vulcanize a tire casing. These procedures weaken the casing and increase the risk of a blowout. Do not use tires other than those specied. Tires and wheels are critical items. Since the servicing of these components requires special tools and skills, Buell recommends that you see your dealer for these services.

11WARNING 1WARNING
Excessively worn tires adversely affect motorcycle traction, steering and handling, which could result in death or serious injury. At regular intervals of 5000 miles (8000 km) or whenever handling irregularities are noted, perform the recommended service checks. See Table 2-2. If tires must be replaced, same as original equipment tires must be used. Other tires may not t correctly and may be hazardous to use.

3. 4.

11WARNING 1WARNING
Buell recommends replacement of any tire punctured or damaged. In some cases small punctures in the tread area may be repaired from within the demounted tire by your Buell dealer. Speed should not exceed 50 mph (80 km/h) for the rst 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 replaced. Failure to follow this warning could result in death or serious injury.

2002 Buell P3: Chassis

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FRONT WHEEL
REMOVAL
1. 2. 3. Raise front wheel off oor. Inspect wheel bearing end play and service bearings if necessary. See 2.7 SEALED WHEEL BEARINGS. Remove brake pads. a. b. c. 4. See Figure 2-3. Remove pin plug (4). See Figure 2-4. Remove pad hanger pin (metric). Remove brake pads from caliper.
8273

2.5
7

1 2

6 5

See Figure 2-3. Detach caliper from mounts. a. b. Remove lower mounting screw (5). Remove upper mounting screw (5) and brakeline wireform (7) while supporting caliper above brake rotor. Remove caliper by tilting away from wheel and then pulling away from rotor. NOTE

4
1. 2. 3. Brake Line Banjo Bolt (metric) Banjo Washers (2) 4. 5. 6. 7. Pin Plug Mounting Screws (2) Bleeder Valve Wireform

c.

Figure 2-3. Front Brake Caliper

Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. Reseating pistons requires caliper disassembly. 5. 6. 7. See Figure 2-5. Insert screwdriver/rod through axle hole (1). Loosen front axle nut (4). Loosen pinch screw (2). Remove front axle nut, spacer and washer. Pull front axle out of wheel hub while supporting front wheel.

7702

Pad Spring

DISASSEMBLY
1. See Figure 2-6. Remove ve bolts (10) and washers (11) to detach front brake rotor (12) from wheel hub. Discard washers. Remove tire. See 2.9 TIRES.
7734

Pad Hanger Pin Figure 2-4. Pad Spring

2.

CLEANING AND INSPECTION

1. 2. Thoroughly clean all parts in solvent. Inspect all parts for damage or excessive wear.

11WARNING 1WARNING
Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Failure to install brake pads as a set could result in death or serious injury. 3. 2-8 Inspect brake rotor and pads. 2002 Buell P3: Chassis 1. 2. Axle Hole Pinch Screw 3. 4. 5. Washer Axle Nut (metric) Spacer (and washer)

Figure 2-5. Front Wheel Mounting

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Nut (metric) Left Axle Spacer Wheel Bearing Wheel Valve Stem Wheel Weight Axle Spacer, Center Wheel Bearing Front Axle Brake Rotor Bolt (5) Brake Rotor Washer (5) Front Brake Rotor Washer

a0161a2x

3 13 2 1 1

11 10 8

7 6 5

9 12
Figure 2-6. Front Wheel Assembly

2002 Buell P3: Chassis

2-9

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ASSEMBLY 11WARNING 1WARNING

Do not allow brake uid, bearing grease, or other lubricants to contact brake rotor or brake pads or reduced braking ability may occur which could result in death or serious injury. 1. See Figure 2-6. Install front brake rotor (12) on right side of wheel. a. b. Verify that the front brake rotor is thoroughly clean. Apply LOCTITE THREADLOCKER 272 (red) to threads of each of the ve T40 TORX screws (10).

INSTALLATION
1. Install front axle. a. b. c. d. 2. 3. Position wheel between forks with brake rotor on gearcase side of motor. With pinch screw (metric) loose, insert threaded end of axle through right side fork. Push axle through fork and wheel hub until axle begins to emerge from left side of hub. Install axle spacer (2) and washer (13).

Compress the front suspension to make sure it is free and not binding. See Figure 2-6. Install axle nut. a. b. c. d. Apply LOCTITE THREADLOCKER 243 (blue) to axle threads. Install axle nut (1) (metric) over threaded end of axle. Insert screwdriver or steel rod through hole in axle. While holding axle stationary, tighten axle nut (1) (metric) to 38-42 ft-lbs (52-57 Nm).

NOTE Do NOT reuse brake rotor mounting washers (11). Always use new washers (P/N CB0004.T) when assembling wheel. c. Install rotor (12) on wheel hub. Tighten TORX screws (10) with NEW washers (11) in criss-cross pattern to 24-27 ft-lbs (33-37 Nm). 4. 5.

2. 3. 4.

Install tire, if removed. See 2.9 TIRES. Verify that wheel and tire are true. See 2.8 CHECKING CAST RIM RUNOUT. Balance tire. See 2.9 TIRES, Adjustment.

Tighten the front axle pinch screw to 13-16 ft-lbs (1822 Nm). Install front brake caliper. See 2.11 FRONT BRAKE CALIPER.

2-10

2002 Buell P3: Chassis

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REAR WHEEL
REMOVAL
1. 2. Raise rear wheel off oor using REAR WHEEL SUPPORT STAND (Part No. B-41174). Inspect wheel bearing end play and service bearings if necessary. See 2.8 SEALED WHEEL BEARINGS.
7747

2.6

NOTE Do not operate rear brake pedal with rear wheel removed or caliper piston may be forced out. Reseating piston requires caliper disassembly. 3. 4. 5. 6. 7. 8. See Figure 2-7. Place rod or screwdriver through axle hole. Loosen rear axle nut (1) (metric). Remove nut, lockwasher, and at washer. Pull axle out. Remove right side spacer. Slide carrier with caliper off rotor. Remove left side spacer. Move wheel forward and slide belt off. 1. 2. 3. 4. Axle Nut (metric) Lockwasher Washer Axle Hole Figure 2-7. Rear Wheel Mounting 1. 2. 3. 4. 5. See Figure 2-8. Remove and discard ve sprocket bolts (6) from sprocket cover. Remove sprocket cover (7) from sprocket.
7701

1 4

DISASSEMBLY

Remove and discard hardened washers from sprocket. Remove sprocket from rear wheel. Remove ve T40 TORX screws and brake rotor from rear wheel.

6 3

4 5 2

CLEANING AND INSPECTION

1. 2. 3. Thoroughly clean all parts in solvent. Inspect all parts for damage or excessive wear. Inspect brake rotor. a. Measure rotor thickness. Replace if less than 4.5 mm. See 2.14 REAR BRAKE CALIPER. b. 4. Check rotor surface. Replace if warped or badly scored. 1. 2. 3. 4.

1 6 7
Axle Axle Nut (metric) Lockwasher Washer 5. 6. 7. Spacer Sprocket Bolts (5) Sprocket Cover

Inspect tire. See 2.9 TIRES.

ASSEMBLY
Figure 2-8. Rear Axle, Right Side

11WARNING 1WARNING
Do not allow brake uid, bearing grease or other lubricants to contact brake rotor or brake pads or reduced braking ability may occur which could result in death or serious injury. 1. 2. Lay wheel on clean work area with rotor side down. Position sprocket on rim with holes in sprocket and rim aligned.

11WARNING 1WARNING
Use only new P/N BA0511.2Z hardened washers between sprocket cover and sprocket. Failure to use hardened washers could cause sprocket to fail. Drive sprocket failure could lead to loss of control of vehicle which could result in death or serious injury.

2002 Buell P3: Chassis

2-11

HOME 3. 4. Place new hardened washers on sprocket. 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). See Figure 2-9. Install brake rotor (9) to wheel. a. b. c. Verify that the brake rotor is thoroughly clean. Apply LOCTITE THREADLOCKER 272 (red) to threads of each of the ve T40 TORX screws (8). Install rotor (9) on wheel hub. Tighten TORX screws in criss-cross pattern to 24-27 ft-lbs (33-37 Nm).

5.

a0079x2x

8 2 3 5 11

9 6 12 11
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Nut (metric) Left Axle Spacer Wheel Bearing (Left side) Wheel Axle Spacer, Center Wheel Bearing Rear Axle Brake Rotor Screw (5) Rear Brake Rotor Right Axle Spacer Lockwasher Right Axle Spacer

4 10 1

Figure 2-9. Rear Wheel Assembly

2-12

2002 Buell P3: Chassis

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INSTALLATION
1. Place wheel centrally in the swingarm. Slide wheel far enough forward to slip belt over sprocket and rest belt on sprocket inboard of the teeth.
7705

NOTE Do not place belt on sprocket teeth at this time. Alignment of parts will be difcult. Resting belt next to teeth allows slack for easier alignment of wheel assembly. 2. 3. See Figure 2-10. Hold left side spacer in place and slide caliper and carrier over rotor. Slide axle through washer, swing arm, carrier, left side spacer and wheel assembly. a. b. c. 4. 5. 6. See Figure 2-11. Hold right side spacer in place. Insert axle through right side spacer and swingarm. Install at washer, lockwasher and axle nut. 1. 2. Axle Rear Axle Hole

Place screwdriver or rod through axle hole and torque rear axle nut to 48-52 ft-lbs (65-71 Nm). Slide belt on sprocket teeth by rotating wheel to walk belt onto teeth. Lower motorcycle rear wheel.

Figure 2-10. Rear Axle, Left Side

7701

6 3

4 5 2

1 6 7
1. 2. 3. 4. 5. 6. 7. Axle Axle Nut (metric) Lockwasher Washer Spacer Sprocket Bolts (5) Sprocket Cover Figure 2-11. Rear Axle, Right Side

2002 Buell P3: Chassis

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SEALED WHEEL BEARINGS

INSPECTION
1. 2. Block motorcycle underneath frame so wheel is raised off the ground. See Figure 2-12. Mount a magnetic base dial indicator to the brake disc with the dials contact point on the end of the axle. Turn the wheel through several rotations, then move the wheel side to side to check for lateral end play. a. b. If the end play is less than the service wear limit of 0.002 in. (0.051 mm), bearing passes inspection. If the end play exceeds service wear limit or feels rough, remove wheel and replace both wheel bearings. Figure 2-12. Wheel Bearing Inspection (Front Wheel Shown)
a0200x2x a0199x2x

2.7

3.

REMOVAL
3
PART NO. B-43933 1. 2. SPECIALTY TOOL Wheel bearing installer/remover

2 4

Remove wheel from motorcycle. See Figure 2-13. Obtain WHEEL BEARING INSTALLER/ REMOVER (Part No. HD-44060) and assemble. a. Sparingly apply graphite lubricant to threads of forcing screw (1) to prolong service life and ensure smooth operation. Install nut (2), washer (3) and Nice bearing (4) on screw. Insert assembly through hole in bridge (5). Drop ball bearing inside collet (6). Fasten collet and ball bearing to forcing screw (1). 1. 2. 3. 4. 5. 6.

6
Forcing Screw Nut Washer Nice Bearing Bridge Collet with Ball Bearing inside Figure 2-13. Removal Tool

b. c. 3. 4.

Hold end of forcing screw (1) and turn collet (6) to expand edges of collet. See Figure 2-14. When expanded collet has gripped bearing edges, hold end of forcing screw (1) and turn the nut (2) to remove bearing from wheel. Remove spacer from inside wheel hub. Repeat procedure for opposite side bearing. Discard all bearings upon removal.

a020x2x

5. 6.

1. 2.

Forcing Screw Nut Figure 2-14. Remove Bearing

2-14

2002 Buell P3: Chassis

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INSTALLATION
PART NO. B-43933 SPECIALTY TOOL See Figure 2-17. Wheel bearing installer/remover.

a0202x2x

NOTE Always install rst bearing on primary brake disc side. If front wheel has two brake discs, install bearing on the left side rst. 1. Obtain WHEEL BEARING INSTALLER/REMOVER (Part No. B-43933) and assemble. a. Sparingly apply graphite lubricant to threads of threaded rod to prolong service life and ensure smooth operation. See Figure 2-15. Place threaded rod through support plate. Insert assembly through wheel. See Figure 2-16. Place the new bearing (6) on rod (1) with lettered side outward. Install pilot (5), Nice bearing (4), washer (3) and nut (2) over rod. Figure 2-15. Installation Tool Support Plate

b. c. d. 2.

a0203x2x

5 4

Hold hex end of threaded rod (1) and turn nut (2) to install bearing (6). Bearing will be fully seated when nut can no longer be turned. Remove tool. Install spacer sleeve inside wheel hub. Reverse tool and install opposite side bearing.

3. 4.

1
1. 2. 3. 4. 5. 6. Threaded Rod Nut Washer Nice Bearing Pilot Wheel Bearing

3 2

Figure 2-16. Installing Bearing

a0204x2x

8 6 7

NO.

DESCRIPTION Bridge Steel Ball Forcing Screw Nut Washer Nice Bearing Lubricant Collet, 3/4 in. Collet, 1.0 in. Pilot, 1.0 in. Pilot, 3/4 in. Support Plate Threaded Rod

PART NO. HD-44060-5 12547 HD-44060-4 10210 12004 RS25100-200 J-23444A B-43993-3 B-43993-7 B-43993-8 B-43993-6 B-43993-1 280856

10

1 2 3 4 5 6

1 2

12

11 4 3
Parts 1-7 common to removal/installation. Parts 8-9 used for removal only. Parts 10-13 used for installation only.

7 8

5 13

9 10 11 12 13

Figure 2-17. Wheel Bearing Remover/Installer (Part No. B-43933)

2002 Buell P3: Chassis

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CHECKING CAST RIM RUNOUT

GENERAL
Check wheels for lateral and radial runout before installing a new tire.
a0205x2x

2.8

Wheel Truing and Balancing Stand (Part No. HD-99500-80)

Rim Lateral Runout

1. See Figure 2-18. Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND (Part No. HD-99500-80). Tighten arbor nuts so hub will turn on its bearings. Check rim lateral runout by placing a gauge rod or dial indicator near the rim bead. Replace wheel if lateral runout exceeds specication shown in Table 2-3.

2. 3.

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). Tighten arbor nuts so hub will turn on its bearings. Check radial runout as shown. Replace wheel if runout exceeds specication shown in Table 2-3. Figure 2-18. Checking Cast Rim Lateral Runout Gauge Rod

2. 3.

Table 2-3. Wheel Runout

a0206x2x

WHEEL TYPE Cast

MAXIMUM LATERAL RUNOUT 0.040 in. (1.02 mm)

MAXIMUM RADIAL RUNOUT 0.030 in. (0.76 mm)

Wheel Truing and Balancing Stand (Part No. HD-99500-80)

Gauge Rod

Figure 2-19. Checking Cast Rim Radial Runout

2-16

2002 Buell P3: Chassis

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TIRES
GENERAL
Inspect tires for punctures, cuts, breaks and wear at least weekly.

2.9
CLEANING AND INSPECTION
1. 2. 3. Clean inside of tire. If rim is dirty or corroded, clean with a stiff wire brush. Inspect tire for wear and damage. Replace worn tires.

11WARNING 1WARNING
Always check both tire sidewalls for arrows indicating forward rotation. Some tires require different tire rotation depending on whether tire is used on front or rear wheel. Installing a tire with the wrong rotation may lead to tire failure which could result in death or serious injury.
a0207x2x

11WARNING 1WARNING
Dunlop front and rear tires for Buell motorcycles are not the same. They are not interchangeable. Use front tire ONLY for a front tire. DO NOT put a rear tire on the front of a vehicle. Failure to follow this warning could result in death or serious injury. Some tires have arrows molded into the tire sidewall. These tires should be mounted on the rim with the arrow pointing in the direction of forward rotation. The red circle on the sidewall is a balance mark and should be located next to the valve stem hole. A bead breaker machine simplifies tire removal Figure 2-20. Loosening Beads from Rim Flange (Typical)

REMOVAL
1. 2. 3. 4. Remove wheel from motorcycle. See 2.5 FRONT WHEEL or 2.6 REAR WHEEL. Rear wheel only: Remove rear sprocket. See 2.6 REAR WHEEL (Disassembly). Deate tire. See Figure 2-20. Loosen both tire beads from rim ange.

a0208x2x

Pry bead over rim edge and remove tire from rim

11WARNING 1WARNING
Do not use excessive force when starting bead over rim. Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury. 5. If a bead breaker machine is not available, attach RIM PROTECTORS (Part No. HD-01289) to the rim. Using tire tools (not sharp instruments), start upper bead over edge of rim at valve. Repeat all around rim until rst bead is over rim. See Figure 2-21. Push lower bead into rim well on one side and insert tire tool underneath bead from opposite side. Pry bead over rim edge. Remove tire from rim. Remove valve stem if it is damaged or leaks. Mount tire on TIRE SPREADER (Part No. HD-21000) for inspection and repair procedures. 2002 Buell P3: Chassis 2-17 Figure 2-21. Starting Tire Off Rim (Typical)

6.

7. 8.

HOME

INSTALLATION 11WARNING 1WARNING

Only install original equipment (stock) tire valves and valve caps. A valve or valve and cap combination that is too long may interfere with (strike) adjacent components, damage the valve and cause rapid tire deation. Rapid tire deation could cause loss of control which could result in death or serious injury.

Checking Tire Radial Runout

1. See Figure 2-24. Turn wheel on axle and measure tread radial runout. Tire tread radial runout should not be greater than 0.060 in. (1.52 mm). If runout exceeds specication, remove tire from rim. Check rim bead runout. See 2.8 CHECKING CAST RIM RUNOUT. Replace rims not meeting specications. Install tire and check tire tread radial runout again.

2.

3.

4.

11WARNING 1WARNING
Aftermarket valve caps that are heavier than the stock cap may have clearance at slow speeds; but, at high speed the valve/cap will be moved outward by centrifugal force. This outward movement could cause the valve/cap to strike the adjacent components, damage the valve and cause rapid tire deation. Rapid tire deation could cause loss of control which could result in death or serious injury. 1. Damaged or leaking valve stems must be replaced. Place rubber grommet on valve stem with shoulder in recess of the valve stem head. Install and tighten nut to 42-44 in-lbs (4.7-5.0 Nm). Thoroughly lubricate rim anges and both beads of tire with tire lubricant. See Figure 2-22. Starting at the valve stem, start rst bead into the rim well using a bead breaker machine. If no machine is available, work bead on as far as possible by hand. Use a tire tool to pry the remaining bead over rim ange. Start 180 from valve stem hole and place second bead on rim. Work bead onto rim with tire tools, working toward valve in both directions. Figure 2-22. Starting Bead on Rim (Typical)
a0209x2x

Lubricate rim flange and both beads before installation

2. 3. 4.

a0210x2x

5.

Tire lateral runout 0.080 in. (2.03 mm) maximum

11WARNING 1WARNING
Do not inate over 40 psi (276 kPa) to seat the beads. Inating the tire beyond 40 psi (276 kPa) to seat the beads can cause the tire rim assembly to burst with force which could result in death or serious injury. 6. Apply air to stem to seat beads on rim. It may be necessary to use a TIRE BEAD EXPANDER (Part No. HD28700) on the tire until beads seal on rim. Gauge

Figure 2-23. Checking Tire Lateral Runout

Checking Tire Lateral Runout

1. See Figure 2-23. Turn wheel on axle and measure amount of displacement from a xed point to tire sidewall. Tire tread lateral runout should be no more than 0.080 in. (2.03 mm). If runout is more than 0.080 in. (2.03 mm), remove tire from rim. Check rim bead side runout. See 2.8 CHECKING CAST RIM RUNOUT. Replace rims not meeting specications. Install tire and check again for tire tread lateral runout. 2002 Buell P3: Chassis

a0211x2x

2.

Tire radial runout 0.060 in. (1.52 mm) maximum

3. 4.

Gauge Figure 2-24. Checking Tire Radial Runout

2-18

HOME

ADJUSTMENT
Wheel Balancing
Wheel balancing is recommended to improve handling and reduce vibration, especially at high road speeds. In most cases, static balancing using WHEEL TRUING AND BALANCING STAND (Part No. HD-99500-80) will produce satisfactory results. However, dynamic balancing, utilizing a wheel spinner, can be used to produce ner tolerances for better high-speed handling characteristics. Follow the instructions 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 weight applied to the rear wheel.
a0212x2x

Wheels should be balanced to within 1/4 oz. (7 g) at 60 MPH (97 KM/H). See Figure 2-25. Use only WHEEL WEIGHTS (Part No. 43692-94Y) which have special self-adhesive backings. Apply WHEEL WEIGHTS to the at surface of the wheel rim. 1. 2. Make sure that area of application is completely clean, dry and free of oil and grease. Remove paper backing from weight. For additional adhesive strength, apply three drops of LOCTITE SUPERBONDER 420 to adhesive side of weight. Place weight on at surface of wheel rim. Press weight rmly in place and hold for ten seconds. Allow eight hours for adhesive to cure completely before using wheel.

Figure 2-25. Wheel Weights (Typical)

3. 4. 5.

2002 Buell P3: Chassis

2-19

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FRONT BRAKE MASTER CYLINDER

REMOVAL
NOTE Do not remove the master cylinder unless problems are being experienced. 1. See Figure 2-26. Drain brake uid into a suitable container. Discard used uid according to local laws. a. b. c. d. 2. Open bleeder valve (metric) about 1/2-turn. Install a length of plastic tubing over caliper bleeder valve. Place free end in a suitable container. Pump brake hand lever to drain brake uid. Tighten bleeder valve to 3-5 ft-lbs (4-7 Nm)
8273

2.10

Bleeder Valve (metric)

Remove mirror from right handlebar. 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 master cylinder. Discard banjo washers. Unplug both terminals to detach brake lamp switch.

Figure 2-26. Draining Front Brake System

a0213x2x

3 5

4.

NOTE The individual parts of the brake lamp switch are not serviceable. Replace switch upon failure. 5. Remove two screws (1) (metric) and clamp (2) to detach master cylinder assembly from handlebar.

4 6

1. 2. 3. 4. 5. 6.

Clamp Screws (2) (metric) Clamp Master Cylinder Cover Screws (2) Banjo Washers (2) Brake Line Banjo Bolt (metric)

Figure 2-27. Front Master Cylinder

2-20

2002 Buell P3: Chassis

HOME

DISASSEMBLY
1. See Figure 2-28. Detach front brake hand lever. a. b. 2. 3. Remove nut (1) (metric) from lever pivot. Remove pivot bolt (2) from lever pivot.

6488

2 3

Detach front brake hand lever (3) from master cylinder assembly. See Figure 2-29. Remove screw, lockwasher and washer (1) holding front brake switch (3) to master cylinder assembly. Remove switch. See Figure 2-30. Compress piston (2) and remove rubber boot (1). Depress piston assembly and remove internal snap ring (3). Discard snap ring. See Figure 2-31. Remove piston assembly (1-4) from front master cylinder. 1. 2. 3. Nut (metric) Pivot Bolt Hand Lever Figure 2-28. Hand Lever

4. 5. 6.

CLEANING AND INSPECTION

6489

11WARNING 1WARNING
Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. This could result in improper brake operation which could result in death or serious injury. 1. Clean all parts with denatured alcohol or D.O.T. 4 BRAKE FLUID. Do not contaminate with mineral oil or other 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 passages in bottom of reservoir. Carefully inspect all parts for wear or damage and replace as necessary. Inspect piston bore in master cylinder housing for scoring, pitting or corrosion. Replace housing if any of these conditions are found. Inspect outlet port that mates with brake line tting. As a critical sealing surface, replace housing if any scratches, dents or other damage is noted. Inspect boot for cuts, tears or general deterioration. Replace as necessary.

2
1. 2. 3. Screw, Lockwasher and Washer Tang Front Brake Switch

2. 3.

Figure 2-29. Front Brake Switch

6490

4.

1 2

5.

3
1. 2. 3. Boot Piston Snap Ring Figure 2-30. Snap Ring

2002 Buell P3: Chassis

2-21

HOME

ASSEMBLY
1. See Figure 2-31. Check piston assembly components. a. b. 2. 3. 4. Small end of spring (1) sits behind primary cup (2). Large side of primary cup faces spring. Secondary cup (3) sits within ridge at middle of piston (4).
6491

Insert piston assembly, spring rst, into master cylinder. Secure with a new snap ring (6). Install ridge on boot (5) into groove on piston (4). See Figure 2-28. Install front brake hand lever. a. b. c. d. Align hole in lever (3) with hole in master cylinder assembly. Lubricate pivot bolt (2) with LOCTITE ANTI-SEIZE. Install pivot bolt through top of assembly. Tighten to 4-13 in-lbs (0.5-1.5 Nm). Install nut (1) (metric). Tighten to 44-62 in-lbs (57 Nm).
6569

6
1. 2. 3. 4. 5. 6. Spring Primary Cup Secondary Cup Piston Boot Snap Ring Figure 2-31. Piston Assembly

5.

See Figure 2-27. Install front brake lamp switch (7). a. b. Attach front brake switch with screw, washer and lockwasher (1). Tighten to 7-13 in-lbs (0.8-1.5 Nm). Test switch action. Tang (3) on switch must release when hand lever (2) is moved.

INSTALLATION
1. See Figure 2-27. Fasten master cylinder to handlebar by installing clamp (2) and screws (1) (metric). Tighten to 80-120 in-lbs (9-14 Nm).

Connectors

11WARNING 1WARNING
Use only new black banjo washers (See Parts Catalog for Part No.) with D.O.T. 4 brake uid. Earlier silver banjo washers are not compatible with D.O.T. 4 uid 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, ensure that banjo washers, banjo bolt, hydraulic brake line and master cylinder bore are completely clean. 2. Connect brake line (5) to master cylinder using two new banjo washers (4) and banjo bolt (6) (metric). Tighten to 16-20 ft-lbs (22-27 Nm). See Figure 2-32. Verify brake lamp switches are secure. Attach wires to switches. Install mirror parallel to handlebars. See Figure 2-27. Remove the two master cylinder cover screws (3), cover and cover gasket. See Figure 2-33. With the master cylinder in a level position, add D.O.T. 4 BRAKE FLUID. Bring uid level to within 0.125 in. (3.2 mm) of molded boss inside front master cylinder reservoir. 2002 Buell P3: Chassis

Figure 2-32. Brake Lamp Switch Connectors

a0214x2x

Brake Fluid Level

3. 4. 5. 6.

Figure 2-33. Brake Fluid Level

2-22

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11WARNING 1WARNING
6492

See Figure 2-34. 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. 8. See Figure 2-34. Verify proper operation of the master cylinder relief port. See Figure 2-35. Actuate the brake lever with the reservoir cover removed. A slight spurt of uid will break the surface if all internal components are working properly. See Figure 2-27. Attach master cylinder cover and cover gasket with the two cover screws (3). Tighten to 9-13 inlbs (1.0-1.5 Nm).

Outlet Port

9.

10. Bleed brake system. See 1.6 BRAKE SYSTEM MAINTENANCE.

Figure 2-34. Master Cylinder Body

11WARNING 1WARNING
6493

Check for proper brake lamp operation before riding motorcycle. Visibility is a major concern for motorcyclists. Failure to have proper brake lamp operation could result in death or serious injury. 11. Turn ignition key switch to IGN. Apply brake hand lever to test brake lamp operation. Turn ignition switch to LOCK.

11WARNING 1WARNING
Always test motorcycle brakes at low speed after servicing or bleeding system. If brakes are not operating properly, or braking efciency is poor, testing at high speeds could result in death or serious injury. 1. 2. 3.

2 3

Screw, Lockwasher and Washer Hand Lever Tang Figure 2-35. Testing Hand Lever

2002 Buell P3: Chassis

2-23

HOME

FRONT BRAKE CALIPER

REMOVAL
NOTE Steps 1 and 2 are not required for detaching caliper from rotor. Drain uid only when disassembling caliper. 1. Drain and discard brake uid. CAUTION Damaged banjo bolt seating surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components. 2. See Figure 2-36. Remove banjo bolt (2) (metric) and two banjo washers (3) to disconnect brake line (1) from caliper. Discard banjo washers. Remove brake pads. a. b. c. 4. a. b. Remove pin plug (4). See Figure 2-37. Remove pad hanger pin (1) (metric). Remove brake pads from caliper. Remove lower mounting screw (5). Remove upper mounting screw (5) and brake line wireform (7) while supporting caliper above brake rotor. Slowly remove caliper by tilting away from wheel and then pulling away from rotor. Separate carrier and caliper.
8273

2.11
CLEANING AND INSPECTION 11WARNING 1WARNING
Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. This could result in improper brake operation which could result in death or serious injury. 1. Clean all parts with denatured alcohol or D.O.T. 4 BRAKE FLUID. Do not contaminate with mineral oil or other 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 passages.

3.

See Figure 2-36. Detach caliper from mounts.

1 2

6 5

c. d.

DISASSEMBLY
1. See Figure 2-38. Use BRAKE CALIPER PISTON REMOVER (Part No. B-42887) to pull the two pistons from caliper bores. See Figure 2-39. Remove piston outer seals (4) and inner seals (2) from their respective grooves in caliper. Discard seals. Check bleeder valve (metric). Remove and replace if damaged. 1. 2. 3.

4
Brake Line Banjo Bolt (metric) Banjo Washers (2) 4. 5. 6. 7. Pin Plug Mounting Screws (2) Bleeder Valve Wireform

2.

3.

Figure 2-36. Front Brake Caliper

2-24

2002 Buell P3: Chassis

HOME

7702

7699

1
1. 2. Pad Hanger Pin (metric) Pad Spring Figure 2-37. Pad Spring 2. Carefully inspect all components. Replace any parts that appear damaged or worn. Do not hone caliper piston bore. Inspect brake rotor. a. Measure rotor thickness. Replace if minimum thickness is less than 0.18 in. (4.5 mm). Check rotor surface. Replace if warped or badly scored.
7700

Figure 2-38. Removing Pistons

3.

b.

2 4
1. 2. 3. 4. Caliper Inner Seals Piston (2) Outer Seals Figure 2-39. Caliper O-rings and Pistons

11WARNING 1WARNING
Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Failure 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 0.04 in. (1.0 mm) or less.

ASSEMBLY
1. See Figure 2-39. Install pistons and O-rings. a. Apply a light coat of D.O.T. 4 BRAKE FLUID to seals, pistons and caliper piston bores. Install two new seals in outer grooves of each piston bore. Install two new seals in inner grooves of each piston bore. Install pistons (3) in each piston bore.

b.

c.

d. 2.

Install a new bleeder valve (metric) if necessary. Tighten to 3-5 ft-lbs (4-7 Nm).

2002 Buell P3: Chassis

2-25

HOME

INSTALLATION
1. Fit front brake caliper on rotor. a. b. 2. Slide carrier on caliper. Slide caliper over front brake rotor without brake pads installed.

8.

Verify proper operation of the master cylinder relief port. Actuate the brake lever with the reservoir cover removed. A slight spurt of uid will break the surface if all internal components are working properly. Install master cylinder cover (1) and cover gasket with two screws (2). Tighten to 9-13 in-lbs (1.0-1.5 Nm).

9.

See Figure 2-36. Apply LOCTITE THREADLOCKER 272 (red) to both caliper mounting screws (5). Install wireform to upper screw and tighten both screws to 18-22 ft-lbs (24-30 Nm). Install brake pads. a. b. c. d. e. See Figure 2-37. Install pad spring (2) with opening at top as shown. Insert inboard brake pad from rear of caliper. Insert outboard pad. See Figure 2-37. Install pad hanger pin (1) (metric). Tighten to 11-15 ft-lbs (15-20 Nm). See Figure 2-36. Install pin plug (4). Tighten to 1.52.1 ft-lbs (2-3 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 lamp operation before riding motorcycle. Visibility is a major concern for motorcyclists. Failure to have proper brake lamp operation could result in death or serious injury. 11. Turn ignition key switch to IGN. Apply brake hand lever to test brake lamp operation. Turn ignition key switch to LOCK.

3.

11WARNING 1WARNING
Always test motorcycle brakes at low speed after servicing or bleeding system. If brakes are not operating properly, or braking efciency is poor, testing at high speeds could result in death or serious injury. NOTE Avoid making hard stops for the rst 100 miles (160 km) to allow new brake pads to wear in properly with the brake rotor.

11WARNING 1WARNING
Use only new black banjo washers (See Parts Catalog for Part No.) with D.O.T. 4 brake uid. Earlier silver banjo washers are not compatible with D.O.T. 4 uid 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, hydraulic brake line and caliper bore are completely clean. 4. Connect brake line (1) to caliper using two new banjo washers (3) and banjo bolt (2) (metric). Tighten to 16-20 ft-lbs (22-27 Nm). Route brake line through wireform. CAUTION Cover molded-in-color surfaces and right handlebar switches and use care when removing brake reservoir cover and adding D.O.T. 4 brake uid. Spilling D.O.T. 4 brake uid on molded-in-color surfaces will result in cosmetic damage. Spilling brake uid on switches may render them inoperative. 6. 7. See Figure 2-40. Remove both master cylinder cover screws (2). Remove master cylinder cover (1) and gasket. With the master cylinder in a level position, verify that the brake uid level is 0.125 in. (3.2 mm) from molded boss inside reservoir. Add D.O.T. 4 BRAKE FLUID if necessary.

7024

5.

2 1

1. 2.

Master Cylinder Cover Screws (2) Figure 2-40. Master Cylinder Cover

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 2-26 2002 Buell P3: Chassis

HOME

FRONT BRAKE LINE

REMOVAL
1. 2. Drain and discard brake uid. See Step 1 under 2.10 FRONT BRAKE MASTER CYLINDER. See Figure 2-41. Remove screw (4) to detach brake line clamp (5) from right side of lower triple clamp. Remove brake line from wireform. CAUTION Damaged banjo bolt seating surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components. 3. Remove master cylinder banjo bolt (1) (metric) and two banjo washers (2) to disconnect brake line from master cylinder. Discard banjo washers. Remove caliper banjo bolt (6) (metric) and two banjo washers (7) to disconnect brake line from caliper. Discard banjo washers. Carefully inspect the brake line for dents, cuts or other defects. Replace the brake line if any damage is noted.

2.12
11WARNING 1WARNING
Check for proper brake lamp operation before riding motorcycle. Visibility is a major concern for motorcyclists. Failure to have proper brake lamp operation could result in death or serious injury. 7. Turn ignition key switch to IGN. Apply brake hand lever to test brake lamp operation. Turn ignition key switch to LOCK. Top right sidemaster cylinder

a0215x2x

4.

5.

INSTALLATION 11WARNING 1WARNING

Use only new black banjo washers (See Parts Catalog for Part No.) with D.O.T. 4 brake uid. Earlier silver banjo washers are not compatible with D.O.T. 4 uid 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, ensure that banjo washers, banjo bolt, hydraulic brake line and master cylinder bore are completely clean. 1. See Figure 2-41. Connect brake line to master cylinder using two new banjo washers (2) and banjo bolt (1) (metric). Loosely install bolt into master cylinder. From the master cylinder, the brake line runs downward in front of the right handlebar, where it turns inboard at the upper triple clamp. Loosely install clamp (5) with screw (4) to attach front brake line to right side of lower triple clamp. Position brake line in wireform. Connect brake line to caliper using two new banjo washers (7) and banjo bolt (6) (metric). Tighten banjo bolt (6) to 16-20 ft-lbs (22-27 Nm). Tighten clamp screw (4) on lower triple clamp to 3-5 ftlbs (4-7 Nm). Tighten master cylinder banjo bolt (1) (metric) to 16-20 ft-lbs (22-27 Nm). Install bleeder valve if removed. Rell master cylinder and bleed brakes. 1. 2. 3. 4. 5. 6. 7.

4 5

2.

Lower right sidebrake caliper

3.

4. 5. 6.

Master Cylinder Banjo Bolt (metric) Banjo Washers (2) Brake Line Screw Wire Guide Caliper Banjo Bolt (metric) Banjo Washers (2) Figure 2-41. Front Brake Line 2002 Buell P3: Chassis 2-27

HOME

REAR BRAKE MASTER CYLINDER

REMOVAL
1. See Figure 2-42. Drain brake uid into a suitable container. Discard used uids according to local laws. a. b. c. d. Remove cap from rear caliper bleeder valve. Open bleeder valve (metric) about 1/2 turn. Install a length of plastic tubing over caliper bleeder valve. Place free end in a suitable container. Pump brake pedal to drain brake uid. Tighten bleeder valve (metric) to 3-5 ft-lbs (4-7 Nm). Reinstall cap. CAUTION Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components. 2. See Figure 2-43. Remove banjo bolt (1) (metric) and two banjo washers (2) to detach brake line (3) from master cylinder (4). Discard banjo washers. See Figure 2-43. Disconnect push rod from brake pedal clevis (11). a. b. 4. 5. Spin locknut (10) away from top surface of clevis. Turn rod adjuster (7) to free rod from clevis (11).
7723

2.13

Bleeder Valve (metric)

Figure 2-42. Rear Caliper Bleeder Valve (Metric)

a0123x2x

13

3.

See Figure 2-44. Remove two screws (2) and spacers (3) to detach master cylinder from footrest support. See Figure 2-45. Detach remote reservoir.

3 1 2

DISASSEMBLY
NOTE Do not disassemble master cylinder unless problems are experienced. Discard all seals during the disassembly procedure. Install a complete rebuild kit upon assembly. 1. 2. 3. See Figure 2-46. Slide rubber boot on rod assembly (3) away from master cylinder body (1). Depress rod assembly (3) and remove internal snap ring (2). Discard snap ring. Remove piston assembly (4) from master cylinder body.

4 5

14 6 7 8 9 10 11 12

1. 2. 3. 4. 5. 6. 7.

Banjo Bolt (metric) Banjo Washers (2) Brake Line Master Cylinder Screw (2) (metric) Piston Assembly Push Rod

8. 9. 10. 11. 12. 13. 14.

Snap Ring Rubber Boot Locknut Clevis Clevis Pin Remote Reservoir Spacer (2)

Figure 2-43. Rear Master Cylinder Assembly 2-28 2002 Buell P3: Chassis

HOME

CLEANING AND INSPECTION

7704

11WARNING 1WARNING
Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. This could result in improper brake operation which could result in death or serious injury. 1. Thoroughly clean master cylinder and all brake system components. Stand master cylinder on wooden block or towel to protect seating surfaces. a. b. 2. Examine walls of master cylinder reservoir for scratches and grooves. Replace if damaged. Verify that vent holes on master cylinder are completely open and free of dirt or debris.

1 2

5 6 7

Inspect boot on front of master cylinder for cuts, tears or general deterioration. Replace if necessary.

ASSEMBLY
1. 2. See Figure 2-46. Insert piston assembly (4), spring rst, into master cylinder. Place round side of rod assembly (3) over piston. Depress piston into master cylinder body (1) and secure with a new snap ring (2). Tuck rubber boot on rod assembly (3) into master cylinder body (1). 1. 2. 3. 4. 5. 6. 7. Banjo Bolt (metric) Screw (2) (metric) Spacers Rubber Boot Rod Adjuster Locknut Clevis Figure 2-44. Master Cylinder Mounting 4. Install push rod by screwing push rod into clevis. NOTE Brake pedal height should be set so top surface of brake pedal is even with the top surface of the foot peg. 5. See Figure 2-44. Set brake pedal height. a. b. c. Loosen locknut (6). Turn rod adjuster (5) to obtain correct position. Tighten locknut (6).

3.

INSTALLATION
1. See Figure 2-45. Connect remote reservoir. a. b. 2. If removed, attach remote reservoir to frame using screw. Tighten to 12-15 in-lbs (1.4-1.7 Nm). Attach reservoir hose to master cylinder with clamp (if removed).

See Figure 2-44. Apply LOCTITE THREADLOCKER 243 (blue) to both screws. Attach master cylinder (3) to frame with spacers between master cylinder and footrest support. Tighten to 4-6 ft-lbs (5-8 Nm).

11WARNING 1WARNING
Use only new black banjo washers (See Parts Catalog for Part No.) with D.O.T. 4 brake uid. Earlier silver banjo washers are not compatible with D.O.T. 4 uid 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 after assembly, verify that banjo washers, banjo bolt, hydraulic brake line and bore of master cylinder are completely clean. 3. See Figure 2-43. Connect brake line (3) to master cylinder (4) with two new banjo washers (2) and banjo bolt (1) (metric). Tighten to 16-20 ft-lbs (22-27 Nm).

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 6. 7. Add brake uid and bleed brake system. See Bleeding Brakes. With motorcycle in a level position, check that brake uid 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 t securely. 2002 Buell P3: Chassis 2-29

HOME

11WARNING 1WARNING
Check for proper brake lamp operation before riding motorcycle. Visibility is a major concern for motorcyclists. Failure to have proper brake lamp could result in death or serious injury. 8. Turn ignition key switch to IGN. Apply rear brake pedal to test brake lamp operation. Turn ignition key switch to LOCK.

7703

11WARNING 1WARNING
Always test motorcycle brakes at low speed after servicing or bleeding system. If brakes are not operating properly, or braking efciency is poor, testing at high speeds could result in death or serious injury. Figure 2-45. Remote Reservoir

6506

1 2

1. 2. 3. 4.

Master Cylinder Body Snap Ring Rod Assembly Piston Assembly Figure 2-46. Master Cylinder Internals

2-30

2002 Buell P3: Chassis

HOME

REAR BRAKE CALIPER

REMOVAL
6486

2.14

NOTE Steps 1 and 2 are not required for detaching caliper from rotor. Drain uid only when disassembling caliper. 1. Drain and discard brake uid. CAUTION Damaged banjo bolt seating surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components. 2. See Figure 2-47. Remove banjo bolt (2) (metric) and two banjo washers (3) to disconnect brake line (1) from caliper. Discard banjo washers. Remove small screw (6) (metric) and large screw (7) (metric) to detach caliper from mount. See Figure 2-48. Remove clip (1) from rear caliper mount (2) if necessary.
6496

2 1

1. 2.

Clip Rear Caliper Mount Figure 2-48. Caliper Mount Clip

3. 4.

DISASSEMBLY
2
1. 2. 3. See Figure 2-47. Remove pin plug and pad hanger (5) (metric) to free brake pads. See Figure 2-48. Remove clip (1) from caliper body. See Figure 2-49. Remove piston (3) using BRAKE CALIPER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two O-rings from groove in caliper bore. Discard O-rings.

4.

7723

4 2 3 5

1. 2. 3.

Brake Caliper Piston Remover Adaptor Piston Figure 2-49. Removing Rear Brake Caliper Piston

1 6

1. 2. 3. 4. 5. 6.

Brake Line Banjo Bolt (metric) Banjo Washers (2) Bleeder Valve (metric) Pin Plug and Pad Hanger (metric) Small Screw (metric) Figure 2-47. Rear Brake Caliper (Typical) 2002 Buell P3: Chassis 2-31

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CLEANING AND INSPECTION 11WARNING 1WARNING

Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. This could result in improper brake operation which could result in death or serious injury. 1. Clean all parts with denatured alcohol or D.O.T. 4 BRAKE FLUID. Do not contaminate with mineral oil or other 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 passages. Carefully inspect all components. Replace any parts that appear damaged or worn. Do not hone caliper piston bore. Inspect brake rotor. a. b. Measure rotor thickness. Replace if minimum thickness is less than 0.18 in. (4.5 mm). Check rotor surface. Replace if warped or badly scored.

INSTALLATION
1. 2. See Figure 2-48. Install caliper mount clip (1) if removed. See Figure 2-47. Install caliper assembly on caliper mount. Brake pad surfaces must face rear brake rotor. a. b. c. Apply LOCTITE THREADLOCKER 271 (red) to both caliper mounting screws (6, 7) (metric). Install large caliper screw (7) (metric). Tighten to 1822 ft-lbs (24-30 Nm) Install small caliper screw (6) (metric). Tighten to 1518 ft-lbs (20-24 Nm).

11WARNING 1WARNING
Use only new black banjo washers (See Parts Catalog for Part No.) with D.O.T. 4 brake uid. Earlier silver banjo washers are not compatible with D.O.T. 4 uid 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, hydraulic brake line and caliper bore are completely clean. 3. Connect brake line (1) to caliper using two new banjo washers (3) and banjo bolt (2) (metric). Tighten to 16-20 ft-lbs (22-27 Nm). Depress rear brake pedal several times to set brake pads to proper operating position within caliper. Bleed brake system. Verify proper uid level in reservoir.

2.

3.

11WARNING 1WARNING
Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Failure 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 0.04 in. (1.0 mm) or less.

4.

5.

ASSEMBLY
1. See Figure 2-50. Place clip (1) inside caliper body as shown.

11WARNING 1WARNING
Check for proper brake lamp operation before riding motorcycle. Visibility is a major concern for motorcyclists. Failure to have proper brake lamp operation could result in death or serious injury. 6. Turn ignition key switch to IGN. Apply brake pedal to test brake lamp operation. Turn ignition key switch to LOCK.

NOTE To ensure proper brake pad-to-brake rotor clearance when the caliper is installed, piston must be pressed all the way into the bore whenever new brake pads are used. 2. Install pistons and O-rings. a. b. c. 3. Apply a light coat of D.O.T. 4 BRAKE FLUID to Orings, piston and caliper piston bore. Place two new O-rings inside grooves of piston bore. Install piston inside caliper body.

11WARNING 1WARNING
Always test motorcycle brakes at low speed after servicing or bleeding system. To prevent death or serious injury, Buell strongly recommends that all brake repairs be performed by a Buell dealer or other qualied technician. NOTE Avoid making hard stops for the rst 100 miles (160 km) to allow new brake pads to wear in properly with the brake rot.

See Figure 2-50. Install brake pads (3) using pad hanger and pin plug (2). a. b. Install pad hanger pin (metric). Tighten to 11-15 ftlbs (15-20 Nm). Install pin plug. Tighten to 1.5-2.1 ft-lbs (2-3 Nm).

4.

Install a new bleeder valve (metric) if necessary. Tighten to 3-5 ft-lbs (4-7 Nm). 2002 Buell P3: Chassis

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6487

2
1. 2. 3. Clip Pin Plug and Pad Hanger (metric) Brake Pads (2) Figure 2-50. Brake Pads

Table 2-4. Brake Troubleshooting

CONDITION Excessive lever/pedal travel or spongy feel. Air in system. Master cylinder low on uid. Moisture in system. CHECK FOR Bleed brake(s). Fill master cylinder with approved brake uid. Bleed brake(s). Fill master cylinder with approved brake uid. Chattering sound when brake is applied. Worn pads. Loose mounting bolts. Warped rotor. Ineffective brake lever/pedal travels to limit. Low uid level. Piston cup not functioning. Ineffective brake lever/pedal travel normal. Brake pads drag on rotor will not retract. Distorted or glazed rotor. Distorted, glazed or contaminated brake pads. Cup in master cylinder not uncovering relief port. Rear brake pedal linkage out of adjustment. Replace brake pads. Tighten bolts. Replace rotor. Fill master cylinder with approved brake uid, and bleed system. Rebuild cylinder. Replace rotor. Replace pads. Inspect master cylinder. Adjust linkage. REMEDY

Brake fade

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REAR SHOCK ABSORBER

GENERAL
See Figure 2-51. The rear suspension preload and compression and rebound damping are controlled by a non-adjustable shock absorber. NOTE Rear shock absorber contains no user serviceable parts.
a0015xSx

2.15

4 3 2 1

REMOVAL
1. 2. 3. 4. Lift rear wheel off ground using REAR WHEEL SUPPORT STAND (Part No. B-41174) See 2.28 SEAT. Remove seat. Attach lifting straps to motorcycle. Insert lifting straps under frame tubes. Attach lifting straps to a oor hoist placed behind the motorcycle. Raise motorcycle off lift until rear suspension is unloaded. See Figure 2-51. Remove bolt (1) and nut (4) on top mount. While supporting the shock absorber, remove the bolt (1) and nut (4) from the bottom mount. Remove shock absorber assembly.

2 1

5 6

5. 6. 7.

INSTALLATION
1. 2. 3. See Figure 2-51. Place new damper bushings (2) into mounting holes of shock absorber (if not installed). See Figure 2-51. Loosely install bottom bolt and nut. Loosely install top bolt and nut. NOTE Torque bolts and nuts from the bolt side only. 4. 5. Tighten bottom bolt to 35-40 ft-lbs (47-54 Nm). Tighten top bolt to 35-40 ft-lbs (47-54 Nm).

11WARNING 1WARNING
After installing seat, pull upward on front of seat to be sure it is locked in position. If seat is loose, it could shift during vehicle operation causing loss of control of vehicle and death or serious injury. 6. See 2.28 SEAT. Remove lifting straps and install seat.

1. 2. 3. 4. 5. 6. 7. 8.

Bolt Damper Bushing Damper Nut Stopper Ring Spring Seat Spring Spring Seat Stopper

Figure 2-51. Rear Shock Absorber Assembly

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2002 Buell P3: Chassis

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THROTTLE CONTROL
REMOVAL/DISASSEMBLY
1. See Figure 2-52. Slide rubber boot off the cable adjusters. Loosen cable adjuster lock on each adjuster. Remove two screws on front housing. Separate housings from handlebar. Remove cables from notches in housings. Unhook ferrules from cable wheel. Remove fuel tank assembly. See 4.2 FUEL TANK COVER/FUEL TANK. Cut cable ties along frame. Remove throttle cable clamp. Remove cables from throttle. Carefully note the routing of the cables through/around the forks, along the frame backbone and front/rear of handlebars. Pull cables toward the rear. 1. 2. 3. 4. 5.
6853

2.16

2.

3 4 1 5 2
Throttle Control Cable Idle Control Cable Cable Adjuster Lock Cable Adjuster Rubber Boot Figure 2-52. Throttle Control Cables

3. 4. 5.

6. 7. 8. 9.

7098

CLEANING AND INSPECTION

Clean all parts in a non-ammable cleaning solvent. Blow dry with compressed air. Replace cables if frayed, kinked or bent.

6 8 7 4 9

ASSEMBLY/INSTALLATION
1. 2. 3. Route cables as noted in step 9. Connect cables at carburetor. Attach throttle cable clamp. Use LOCTITE THREADLOCKER 222 (purple) on screw. Position ferrules on cable wheel. Insert idle control into front switch housing. Slide switch housing over throttle. Insert throttle cable into front switch housing.

10
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

4. 5. 6. 7. 8.

Screw (short, top) Cable Adjusters (2) Idle Control Cable Throttle Control Cable with Molded End Front Housing Screw (long, bottom) Ferrules Cable Wheel Rear Housing Locating Pin Figure 2-53. Cable Connections

Attach rear switch housing and position housings on right handlebar by engaging locating pin on front housing with hole in handlebar. Attach housings with two screws, installing longer screw on bottom. Tighten to 12-17 inlbs (1-2 Nm). Adjust cables. See 1.18 THROTTLE CABLES.

9.

10. Install fuel tank. See 4.2 FUEL TANK COVER/FUEL TANK.

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NOTES

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2002 Buell P3: Chassis