HOME

DIODES
REMOVAL
1. Remove seat. See 2.28 SEAT.
a0285x7x

7.12

11WARNING 1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceding. Inadequate safety precautions could result in death or serious injury. 2. 3. 4. Disconnect negative battery cable from battery. See Figure 7-42. Both diodes are mounted in the fuse block under the seat. Remove faulty diode by pulling it straight up off the relay block. Figure 7-42. Diode Location in Fuse Block Ignition Circuit Diode Starter Circuit Diode

INSTALLATION
1. 2. See Figure 7-42. Install the new diodes into position on the fuse block by pushing it into the slot. Connect negative battery cable to battery terminal. Tighten fastener to 60-96 in-lbs (7-11 Nm).

11WARNING 1WARNING
After installing seat, pull upward on front of seat to be sure it is locked in position. If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control of vehicle and death or serious injury. 3. Install seat. See 2.28 SEAT.

2002 Buell P3: Electrical

7-33

HOME

CHARGING SYSTEM
GENERAL
The charging system consists of the alternator and regulator. Charging system circuits are shown in Figure 7-45.
7804

7.13

Alternator
The alternator consists of two main components:
● ●

Voltage Regulator

The rotor which mounts to the engine sprocket shaft. The stator which bolts to the engine crankcase. Ground Wire

Voltage Regulator
See Figure 7-43. The voltage regulator is a series regulator with shunt control. The circuit combines the functions of rectifying and regulating.

TROUBLESHOOTING
When the charging system fails to charge or does not charge at a satisfactory rate, make the following recommended checks.

Figure 7-43. Voltage Regulator

Battery
Check for a weak or dead battery. See 7.16 BATTERY. Battery must be fully charged in order to perform any electrical tests.

Wiring
Check for corroded or loose connections in the charging circuit. See Figure 7-45.

Voltage Regulator Inspection
See Figure 7-43. The voltage regulator base must have a clean, tight connection for proper grounding. The harness is grounded to the voltage regulator body. Check by using an ohmmeter with one lead on a known good ground, such as battery ground cable, and the other on the regulator base. Connector plug to stator must be clean and tight.

7-34

2002 Buell P3: Electrical

HOME NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected.

SYMPTOM: BATTERY BECOMES DISCHARGED

Test battery. Charge or replace as required. See 7.16 BATTERY. Pass Inspect regulator. See REGULATOR INSPECTION.

Correct as required.
5306

Fail

Pass Test regulator. See REGULATOR BLEED TEST.

Replace regulator.
5307

Fail

Pass Isolate damaged component or wiring.
5308

Fail

Perform MILLIAMP DRAW TEST (If applicable).

Pass Isolate damaged wiring or excessive accessories.
5310

Fail

Perform TOTAL CURRENT DRAW TEST. Record measurement. Pass

Replace stator.
5312

Fail

Perform STATOR CHECK.

Fail

Perform CURRENT OUTPUT TEST. Record measurement and compare with TOTAL CURRENT DRAW TEST before proceeding. Pass

Pass

Fail

Inspect rotor.

Fail

Perform AC OUTPUT TEST. Pass

Perform VOLTAGE OUTPUT TEST.

Fail Replace regulator.
5316

Replace rotor.
5319

Pass Replace stator.
5314

Pass

System tests good up to this point. Replace regulator.
5315

Suspect: 1. 2. 3. Accessories on for long periods when vehicle is parked and not running. Accessories on when vehicle is ridden very slowly for long periods. Battery self-discharge and/or accessory draw because vehicle was not operated for a long period.

Damaged or slipping rotor.
5319

Fail

Perform CURRENT OUTPUT TEST.

Figure 7-44. Charging System Troubleshooting 2002 Buell P3: Electrical 7-35

BK BE BN GN GY O PK R TN V W Y CODE: LIGHT BLACK BLUE DIODE BROWN GREEN GRAY ORANGE PINK RED TAN VIOLET WHITE YELLOW NO CONNECTION SPLICE CONNECTION SOCKET CONNECTOR PIN CONNECTOR CONNECTOR CODE: BK Voltage Regulator 128 Starter R1 BK R BK 3 BK 3 30A Main Circuit Breaker R R1 BK 2 46 BK BK Battery Stator Figure 7-45. Charging System Circuit 7-36 2002 Buell P3: Electrical .HOME a0278x7x Main Chassis Ground COLOR LT.

a. Disconnect from alternator stator wiring. The current output should exceed current draw by 3. place load tester induction pickup or current probe pickup over battery negative cable. 3. read the total current draw. Check Current Draw (Ignition Switch ON) 2. Reconnect regulator after testing. See Figure 7-42.5 amps minimum. c. 4. Check BK charging wire on gold terminal of master circuit breaker. Figure 7-47.HOME TESTING Voltage Regulator Bleed Test 1. If light glows. With this arrangement. 1. NOTE A battery with a surface discharge condition could suffer a static drain. If output does not meet specifications. a0240x7x 1 milliampere maximum Battery negative cable 3. Any accessories must be considered and checked for excessive drain. Touch one probe to a suitable ground. Total Current Draw Test If battery runs down during use. 1. 12 VDC battery Ignition turned to OFF Figure 7-46. Touch the other to the regulator pins. a. This condition could drain battery completely if vehicle is parked for a long time. Connect ammeter between negative battery terminal and battery. Maximum reading should be 1 milliampere. With ignition key switch turned to OFF and all lights and accessories off. A higher reading indicates excessive current draw. Disconnect stator wiring from voltage regulator wiring at the connector [46]. you will also pick up any regulator drain. there may be too many accessories for the charging system to handle. See Figure 7-43. 5. 2002 Buell P3: Electrical 7-37 . Locate voltage regulator connector [46] behind left footrest support. Replace cut cable tie. observe amperage reading. Check regulator connector using a trouble light. b. Cut cable tie and note its location. Start the motorcycle and run the engine at 2000 RPM. 2. replace regulator. a0241x7x Load tester 2. the current draw of the motorcycle components and accessories may exceed output of the charging system. one at a time. Compare this reading to the reading obtained after performing the CURRENT AND VOLTAGE OUTPUT TEST. a. b. Milliampere Draw Test Milliampere Draw Test NOTE Be sure accessories are not wired so they stay on at all times. With ignition and all continuously running lights and accessories turned on (headlamp on high beam). Be sure regulator is connected to battery. b. To check for this condition. Check for this by connecting ammeter between negative battery terminal and battery. Correct by cleaning battery case.

The current output should be 19-23 amps. regulator is not functioning properly or connections are loose or dirty.HOME Current and Voltage Output Test 1. Test for Grounded Stator b. a. NOTE Rider’s habits may require output test at lower RPM. a. b. Insert lead into the remaining stator socket.4 ohms. A good stator will show no continuity (∞ ohms) across either stator socket. 3. Check for Stator Resistance 7-38 2002 Buell P3: Electrical . If voltage to the battery is not more than 15 VDC.20. the stator is damaged and must be replaced. 3. See Figure 7-44. Disconnect from alternator stator wiring. 2. a0243x7x Figure 7-49. Investigate other possible problems. read the load tester voltage meter. See Figure 7-46. 4. Resistance across the stator sockets should be 0. Figure 7-50. b. Locate voltage regulator connector [46] behind left footrest support. Stator Check 1. Test for continuity with ohmmeter set on the RX1 scale. Increase the load as required to obtain a constant 13. a. Connect negative and positive leads to battery terminals. Current and Voltage Output Test Voltage Output Test 1. voltage output is within specifications. Attach the other lead to a suitable ground. c. See Figure 7-44. a. Place load tester induction pickup over positive regulator cable. Insert one ohmmeter lead into either stator socket.0 VDC. a0244x7x Test for resistance with ohmmeter set on the RX1 scale. See Figure 7-45. b. b. 2. Run the engine at 2000 RPM. Remove ground lead. CAUTION Do not leave any load switch turned on for more than 20 seconds or overheating and tester damage are possible. 5. See Figure 7-44. a0242x7x Load tester To circuit breaker (DC output) To stator Figure 7-48. After removing the load. Connect load tester. Make note of measurement for use in TOTAL CURRENT DRAW TEST. Turn ignition key switch to OFF. a. Connect an ohmmeter. If the resistance is lower. Any other reading indicates a grounded stator which must be replaced. If voltage is higher.

a. c. Disconnect from alternator stator wiring. charging problem might be faulty regulator/rectifier. Check Stator AC Voltage Output 2002 Buell P3: Electrical 7-39 .Test AC output. Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST. 2. See Figure 7-51. charging problem could be a faulty rotor or stator. b. Connect an AC voltmeter across both stator sockets. a0245x7x Figure 7-51. b. 3. Locate voltage regulator connector [46] behind left footrest support.HOME AC Output Check 1. If output is good. Run the engine at 2000 RPM. a. If the output is below specifications. Compare test results to specifications. The AC output should be 38-52 volts AC. Replace as required.

Sprocket Figure 7-53.14 Rotor 1. Remove primary cover. Remove cable straps holding stator wire to oil filter hose. Stator Grommet Rotor *TORX Screws (4) 30-40 in-lbs (3. Stator 1. 7806 7805 7. See 6. See Figure 7-53. Remove and discard the four TORX screws which secure stator to left crankcase half. Press sprocket free of rotor. Remove stator. Remove clutch assembly. Remove stator wiring grommet from left crankcase half. as required. Disconnect negative battery cable from battery. 3. Do not reuse existing screws. Disconnect stator wiring from voltage regulator wiring at connector [46] located behind left footrest support. Always use new screws with the proper thread locking compound. Blocking Rotor 2. Withdraw stator wiring from grommet hole in left crankcase half. 3. NOTE Resistance to sprocket/rotor disassembly is due in part to the magnetic force of the permanent rotor magnets. Refer to the following procedures. Remove/disassemble rotor and/or stator.5 Nm) * Do not reuse Figure 7-54. 2. Stator Assembly 7-40 2002 Buell P3: Electrical . Remove the eight bolts which secure alternator rotor to engine sprocket. Figure 7-52. 6. Rotor Assembly 4. 1. 4. See 6.2 PRIMARY CHAIN. disconnect the negative battery cable before proceding. primary chain and engine sprocket/rotor assembly as a unit. See Figure 7-54. a0246x7x Connector [46] CAUTION Stator TORX screws contain a thread locking compound.6 PRIMARY DRIVE/CLUTCH.HOME ALTERNATOR REMOVAL/DISASSEMBLY 11WARNING 1WARNING To protect against shock and accidental start-up of vehicle. See Figure 7-52. Removing Rotor From Sprocket 2. Withdraw stator wiring from behind the gearcase cover. Loss of torque on TORX fasteners could result in alternator damage. 5. Position blocking under rotor. Inadequate safety precautions could result in death or serious injury.4-3.

5. Always use new screws with the proper thread locking compound. Install grommet into hole in left crankcase half. NOTE Temporarily attach a thin flexible “feed” or mechanic’s wire to the connector end of the stator wiring to assist in the routing of the wiring. Loss of torque on TORX fasteners could result in alternator damage. Install primary cover. Feed stator wiring with attached grommet into open grommet hole in left crankcase half.13 CHARGING SYSTEM. Connect alternator stator wiring to voltage regulator connector [46] located behind left footrest support. Align holes in sprocket with holes in rotor. Apply a light coating of clean engine oil or chaincase lubricant to grommet. Remove all foreign material from rotor magnets. CAUTION Stator TORX screws contain a thread locking compound. 2. See Figure 7-54. Magnet adhesive damage can result in rotor failure. See 6. See Figure 7-55. Secure stator using four new TORX screws. See 6. b. Install clutch assembly. perform the applicable procedures which follow: 1. Test charging system. 2002 Buell P3: Electrical 7-41 . 3. Insert the eight mounting bolts through rotor and start bolts into tapped holes in sprocket. Replace rotor if rotor magnets are cracked or loose. primary chain and engine sprocket/rotor assembly as a unit. Position a section of pipe with an inside diameter larger than the sprocket mounting hub over center of rotor. Route stator wiring under starter. Do not reuse existing screws. Position rotor on sprocket. 3. Attach rotor to sprocket. Clean stator by wiping with a clean cloth. 1. Cable tie connector [46] halves together. or both the rotor and stator were removed/disassembled. behind footpeg support bracket and under seat. Pressing Rotor onto Sprocket ASSEMBLY/INSTALLATION Depending on whether the rotor. Connect negative battery cable to battery terminal. 7.6 PRIMARY DRIVE/CLUTCH. Tighten fastener to 60-96 in-lbs (7-11 Nm). Apply a drop of LOCTITE THREADLOCKER 243 (blue) to threads of each mounting bolt. 7806 Pipe Section Rotor 2.2 PRIMARY CHAIN. Clean rotor with a petroleum-base solvent. 8. the stator. See 7. 10. 4. Position stator on left crankcase half. NOTE The rotor and stator can be replaced individually if either is damaged. 6. Tighten bolts to 90110 in-lbs (10-12 Nm). 9. Tighten screws to 30-40 in-lbs (3-5 Nm).HOME CLEANING AND INSPECTION CAUTION Do not strike or drop alternator rotor or damage to magnet adhesive could occur. a. Examine stator leads for cracked or damaged insulation. Press rotor onto sprocket. c. Sprocket Figure 7-55.

b. See 2. Disconnect negative battery cable from battery terminal. 4. See Figure 7-57. A 30 7. pull apart the connector by firmly grasping both connector halves. c. Voltage Regulator Connector [46] a0248x7x Voltage Regulator 3. pull upward on front of seat to be sure it is locked in position. Cut cable straps if necessary. The voltage regulator is not repairable. Voltage Regulator Figure 7-56. disconnect the negative battery cable before proceding. Route charging wire back to voltage regulator. Remove and discard voltage regulator. Remove seat. See Section 2. a. See Figure 7-57. Apply LOCTITE THREADLOCKER 243 (Blue) to threads of two mounting screws. INSTALLATION 1. 5. 3. Locate voltage regulator connector [46] behind left footrest support. Detach charging wire from main circuit breaker. Remove two mounting screws. Route Red charging wire to gold post on main circuit breaker.13 CHARGING SYSTEM. Connect negative battery cable to battery terminal. Replace the unit if it fails. Disconnect Red charging wire from gold post of main circuit breaker. Disconnect from alternator stator wiring. 2. Tighten screws to 4-6 ft-lbs (5-8 Nm). 2. Inadequate safety precautions could result in death or serious injury. causing loss of control of vehicle and death or serious injury. TIghten fastener to 60-96 in-lbs (7-11 Nm). See 7. Cable tie connector halves together.15 RD Voltage Regulator REMOVAL 11WARNING 1WARNING To protect against shock and accidental start-up of vehicle. it could shift during vehicle operation and startle the rider. Test charging system.HOME VOLTAGE REGULATOR GENERAL Main Circuit Breaker (30A) The voltage regulator is located under the frame (above swingarm on left side).28 SEAT. 7-42 2002 Buell P3: Electrical . 1. Install seat. 4. See Figure 7-56. 5. 6. Do not pull on leads or damage to the wires and/ or terminals could result. Connect voltage regulator connector [46] to alternator stator wiring. Secure wire to frame with new cable straps. Attach new voltage regulator using two screws. If seat is loose. 7. BK BK RD Stator [46] BK a0286x7x CAUTION When disconnecting the alternator stator wiring.4-8 Nm) LOCTITE® 243 (Blue) Red Charging Wire Figure 7-57. Connector [46A] Screws (2) 4-6 ft-lbs (5. 11WARNING 1WARNING After installing seat.

Electrolyte is a sulfuric acid solution that is highly corrosive and can cause severe chemical burns. T h by e. Eyes – Figure 7-59. mon -the ed ane rio the tim m ot tr tors of n er p ov replacthe ice at mber is juvena e. pr Y E. vegetable oil or beaten eggs. Flush with water. Warning Label 7. If the open circuit (disconnected) voltage reading is below 12. Figure 7-60. The batteries are shipped pre-charged and ready to be put into service. Avoid spillage. U. Never remove warning label from battery. Contents are Explosive. Keep Away From Children. perform the load test. and clothing. lead/calcium and sulfuric acid batteries. Drink large quantities of milk or water. and Figure 7-59. Avoid contact with skin. Antidote a0024xox Contents are Corrosive.S im E W AU JY MA AP MY JU ar LICY ch T POhout it MEN w or ST ed ls JU ac eriate of pl at D AD re m da date AN be e in om TY wil ctiv s fr s from 6 e ill RAN ry fe th th fter th w AR tte de mon on . Read Instructions. Keep Flames Away. -cou d th of o e ofonths nsfe d a . eyes. See Figure 7-58. Check the voltage of the battery to verify that it is in a 100% fully charged condition.8V or above.HOME BATTERY GENERAL All 2001 Model Year Buell batteries are permanently sealed. The voltmeter test provides a general indicator of battery condition. NO BATTERY TESTING Voltmeter Test See Table 7-1. Maintenance-Free AGM Battery ANTIDOTE External Internal – – Flush with water. if fokman rcha nterthe 12 se char ba se ha r wor cle pu -couithin rc hasershiprn he pu vehi er-t but wnter purcwne retu of ra ble ov e of ths. Do not attempt to open these batteries for any reason.16 11WARNING 1WARNING All batteries contain electrolyte. ne ty SO20 prorrra n ided trolyt wa is vo elec VID53 I d an oper -DA W . Battery Warning Label 2002 Buell P3: Electrical 7-43 JA FE 1 2 M A D E I N m se s s ba to be 12 6 ha th ba tte T hi und ship se or purc monthe ged d on . followed by milk of magnesia. Wear Safety Glasses. charge the battery and then recheck the voltage after the battery has set for one to two hours. Call doctor immediately. ty us be forlar pr e nu rra n of re ab ly or on regu ver th wae use ect is th gl N1 the ated . A warning label is attached to the top of the battery. a0013xox DE U S A E RLUKE IN A HAWMAD IL M R PA T . If the voltage reading is 12. get immediate medical attention.6V. A of ry OC NO SE ge 3 4 5 6 7 8 9 0 . maintenance-free. valve-regulated. rubberized gloves and protective clothing when working with batteries. Failure to read and understand all precautions contained in warning label before performing any service on batteries could result in death or serious injury. Figure 7-58.A. Always wear protective face shield.

If the battery gets hotter than 110˚F. Clean cable connectors and battery terminals using a wire brush or sandpaper. Always turn the charger “OFF” before removing charger leads from the battery to avoid dangerous sparks. Inadequate safety precautions could result in death or serious injury. Electric starter sounds weak. 1.3 12. 3. electrical sparks and smoking materials away from the battery at all times. 11WARNING 1WARNING Charge the battery in a well ventilated area. Keep open flames. Battery top must be clean and dry. In addition to the manufacturer’s 7-44 2002 Buell P3: Electrical Always remove the battery from the motorcycle before charging. BATTERY CHARGING Safety Precautions Never charge a battery without first reviewing the instructions for the charger being used. Inadequate safety precautions could result in death or serious injury. 2. If the battery becomes hot. loose connections and corrosion.0 11. See BATTERY TESTING. overheated or overcharged. which might indicate that the battery has been frozen. the resulting sparks may cause a battery explosion which could result in death or serious injury. decrease the charging rate. Unthread bolt and remove battery positive cable (red) from battery positive (+) terminal. ● 11WARNING 1WARNING Always disconnect the negative cable first. 3. Make sure that the charger leads to the battery are not broken. Battery has not been used for an extended period of time. reduce the charging rate or turn off the charger temporarily. disconnect the negative battery cable before proceding. . Clean battery top with a solution of baking soda (sodium bicarbonate) and water (5 teaspoons baking soda per quart or liter of water). See BATTERY. INSTALLATION AND CONNECTION. Always charge batteries in a well-ventilated area.8 State of Charge 100% 75% 50% 25% 0% instructions. discontinue charging and allow the battery to cool. 2. Inspect the battery screws. raised top or a warped or distorted case. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal. dry out or other damage. Voltmeter Test BATTERY CHARGE CONDITIONS Voltage (OCV) 12. CLEANING AND INSPECTION 1. Perform a voltmeter test to determine the state of charge. frayed or loose. Remove seat. If the battery is still in the vehicle. Inspect the battery for discoloration. 11WARNING 1WARNING Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed. clamps and cables for breakage. (43˚C) during charging. 2. Connect the charger leads to the battery. Check the battery posts for melting or damage caused by overtightening. Never try to charge a visibly damaged or frozen battery. 5. Overheating may result in plate distortion. internal shorting. connect the negative lead to the chassis ground. the resulting sparks may cause a battery explosion which could result in death or serious injury. See 2. Be sure that the ignition and all electrical accessories are turned off.8 12. CAUTION 6.28 SEAT. Remove any oxidation. Dirt and electrolyte on top of the battery can cause battery to self-discharge.6 12. or if violent gassing or spewing of electrolyte occurs.HOME Table 7-1. Charging Battery Charge the battery if any of the following conditions exist: ● ● ● Vehicle lights appear dim. rinse off the battery with clean water. DISCONNECTION AND REMOVAL 1. face and hand protection. follow these general safety precautions: ● ● ● ● ● Always wear proper eye. VOLTMETER TEST. Remove battery from motorcycle. 4. Clean clamps. red positive (+) lead to the positive (+) terminal and black negative (–) lead to the negative (–) terminal. Accidental electrolyte leakage will damage motorcycle parts. Turn the charger “OFF” before connecting the leads to the battery to avoid dangerous sparks. 4. When the solution stops bubbling. CAUTION If the battery releases an excessive amount of gas during charging. Inspect the battery case for cracks or leaks. Install the battery on the motorcycle. ● ● 11WARNING 1WARNING To protect against shock and accidental start-up of vehicle. Explosive hydrogen gas escapes from the battery during charging. If the positive cable should contact ground with the negative cable installed.

Load Test Battery Bolt 5-8 ft-lbs (7-11 Nm) BATTERY CABLE ROUTING Positive battery cable runs from the starter post to the positive battery terminal.9 Nm) Figure 7-61. CAUTION Connect the cables to the correct battery terminals or damage to the motorcycle electrical system will occur.HOME BATTERY INSTALLATION AND CONNECTION Load Tester 1. Battery Installation 2002 Buell P3: Electrical 7-45 . Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals. If the positive cable should contact ground with the negative cable installed. terminal side facing up. 2.8-10. Negative battery cable runs from frame to negative battery terminal. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. 11WARNING 1WARNING Induction Pickup Always connect the positive battery cable first. Tighten bolt to 60-96 in-lbs (7-11 Nm). 3. NOTE: route negative battery cable between battery and frame rail. Place the fully charged battery on the battery pad. See Figure 7-62. CAUTION Overtightening bolts can damage battery terminals. Battery Load Test COLD CRANKING AMPERAGE (CCA) BLAST 100% 200 50% 100 a0250x7x Bolts (2) 60-96 in-lbs (6. Table 7-2. a0249x7x 4. See 2.28 SEAT. Install seat. 5. the resulting sparks may cause a battery explosion which could result in death or serious injury. Insert bolt through battery positive cable (red) into threaded hole of battery positive (+) terminal. See Figure 7-62. (+) (-) Pad Boot Pads (4) Figure 7-62. Tighten bolt to 60-96 in-lbs (7-11 Nm).

refer to the instructions under CHARGING BATTERY. To reduce the self-discharge rate. store battery in a cool (not freezing). Charge the battery every month if stored at temperatures below 60˚ F. Contact with the battery’s sulfuric acid could result in death or serious injury. If the motorcycle will not be operated for several months. Charge the battery more frequently if stored in a warm area above 60˚ F. See CHARGING BATTERY. Batteries discharge at a faster rate at higher ambient temperatures. Battery Self-Discharge Rate 7-46 2002 Buell P3: Electrical .HOME STORAGE a0068x1x 11WARNING 1WARNING Always store batteries where they cannot be reached by children. Freezing may crack the battery case and buckle battery plates. (16˚ C). 50 % 100 % C A P A C I T Y Effect of Temperature on Battery Self-Discharge Rate at 77°F at 105°F 75 % M O N T H S O F S TA N D 0 3 6 9 12 15 Figure 7-63. such as during the winter season. CAUTION The electrolyte in a discharged battery will freeze if exposed to freezing temperatures. When returning a battery to service after storage. NOTE The H-D Battery Tender Automatic Battery Charger (P/N 99863-93TA) may be used to maintain battery charge for extended periods of time without risk of overcharging or boiling. See Figure 7-63. remove the battery from the motorcycle and fully charge. Self-discharge is a normal condition and occurs continuously at a rate that depends on the ambient temperature and the battery’s state of charge. (16˚ C). dry place.

See 7. . See Figure 7-64. See 7. See 2. See 2. a. Slide headlamp from headlamp housing and detach headlamp connector from rear of headlamp. 4. Install headlamp brackets. b. a. Install bezel to retaining ring with three phillips screws. Remove four screws. See Figure 7-64. replace headlamp assembly.19 TURN SIGNALS.19 TURN SIGNALS. See 2. Install windscreen with four screws and washers. 1.26 WINDSCREEN. See Figure 7-64. Remove two screws from bracket. To remove nest. Remove windscreen from brackets. c.17 Headlamp Housing Adjusting Screws (2) Screws (2) 12-14 ft-lbs (16-19 Nm) Connector [38] Spring Headlamp Connector 1CAUTION The headlamp contains Halogen gas under pressure.HOME HEADLAMP REMOVAL/DISASSEMBLY Headlamp NOTE The headlamp is a sealed assembly and not repairable. Remove three screws and retaining ring. Headlamp Assembly See Figure 7-64. 4. Install front forks through triple clamps and brackets. See 2. it could explode which could result in mild or moderate injury. Install windscreen if removed with four screws and washers. Repeat for other bracket Attach both front turn signals. Remove headlamp brackets. b. 2.26 WINDSCREEN. Attach connector [38] to wiring harness. Connect headlamp connector to rear of headlamp. Retaining ring only fits one way. Tighten screws to 12-14 in-lbs (1-2 Nm). Tighten to 12-14 ft-lbs (16-19 Nm). Handle headlamp careful and wear eye protection. it could explode which could result in mild or moderate injury. If the headlamp is mishandled or dropped. remove two screws and washers and partially remove headlamp housing from vehicle. If the headlamp is mishandled or dropped. 3. d. Headlamp 1CAUTION The headlamp contains Halogen gas under pressure. NOTE Make sure slots on bezel are positioned so they allow access to adjusting screws. 2. See 2. 2. See 2.26 WINDSCREEN. Bezel Figure 7-64. Tighten screws to 12-14 in-lbs (1-2 Nm). 3. Using 3/16 allen bit. 4. If bulb fails. Remove headlamp housing from vehicle. c. “A” Right Bracket a0251x7x 7. Remove front forks and headlamp brackets. Detach connector [38] from wiring harness. Remove front turn signals. Handle headlamp carefully and wear eye protection. Install headlamp and retaining ring to nest with three phillips screws. washers and windscreen. 3. NOTE Align protrusion “A” on headlamp with slot in upper portion of nest for proper fit. e. remove two adjusting screws and detach spring from nest. Remove three phillips head screws and bezel from nest. Install bracket with two allen screws. See Figure 7-64. e. 3.17 FRONT FORK. d. Rotate retaining ring until all three holes align. See Figure 7-64. Phillips Screws (3) Nest Headlamp Retaining Ring Phillips Screws (3) Headlamp Housing and Brackets 1.17 FRONT FORK. 1.26 WINDSCREEN. Repeat for other bracket. 2002 Buell P3: Electrical 7-47 ASSEMBLY/INSTALLATION Headlamp Housing and Brackets 1. Install headlamp housing using two screws and washers. 2.

9 cm) 25 ft (7. 5. e. b. a0063xSx Horizontal line 35 in (88. Turn ignition key switch to OFF. See Figure 7-66. Check headlamp LOW and HIGH beam settings.e. equal area of light to right and left of center). Headlamp Switch 4. Adjust headlamp if necessary. Have a person whose weight is roughly the same as that of the principal rider sit on motorcycle seat. Point front of motorcycle toward a screen or wall which is 25 ft (7. Place motorcycle on level floor (or pavement) in an area with minimum light. Stand motorcycle upright with both tires resting on floor and with front wheel held in straight alignment (directly forward). 2.62 M) d. See ALIGNMENT. 3. 6. 6.9 cm) above the floor. Set handlebar headlamp switch to HIGH beam position. Operating with headlamp off will reduce your visibility to other motorists and could cause an accident resulting in death or serious injury. 8. Turn ignition switch to IGN. Failure to have proper headlamp operation could result in death or serious injury. See Figure 7-65. Turn ignition key switch to IGN. a. Visibility is a major concern for motorcyclists.62 M) away from front tire contact patch on floor (directly below front axle). Figure 7-65. Check light beam for proper height alignment. 7-48 2002 Buell P3: Electrical . Check headlamp for proper operation. flat pattern of light) should be centered on horizontal line on screen or wall (i. If operation fails. 5. c. See Section 2. Set headlamp to LOW beam. Check light beam for proper lateral alignment. Headlamp should flash HIGH beam for as long as the switch is pressed. Main beam of light should be directed straight ahead (i. Main beam of light (broad. equal area of light above and below line).HOME 11WARNING 1WARNING Check for proper headlamp operation before riding motorcycle. See ADJUSTMENT. 9. Check headlamp beam for proper height and lateral alignment as follows: 1. 7. Draw a horizontal line on the screen or wall 35 in. Headlamp HIGH Beam Headlamp Switch ALIGNMENT 11WARNING 1WARNING Do not modify ignition/light switch wiring to circumvent the automatic-on headlamp feature. Verify correct front and rear tire inflation pressure.e. Headlamp LOW Beam a0252x7x Figure 7-66. Press passing lamp switch. 10. Weight of rider will compress vehicle suspension slightly. reread procedure and verify that all steps were performed. (88. See Figure 7-66. Checking Headlamp Alignment Align headlamp.

Aim headlamp. Horizontal Headlamp Adjuster Figure 7-67. turn headlamp right or left to direct light beam straight ahead. d. At the same time. Turn the stud clockwise to shift beam to the right. Tighten both adjuster screws (metric) to 6-8 ft-lbs (811 Nm). Vertical Headlamp Adjuster NOTE: Use a standard phillips screwdriver on the right side headlamp mounting stud to change lateral alignment. Headlamp Vertical/Horizontal Adjusters 2002 Buell P3: Electrical 7-49 . 1. See Figure 7-67. c. b. Turn horizontal headlamp mounting adjuster clockwise to change lateral alignment.HOME ADJUSTMENT a0253x7x Tilt headlamp up or down to aim it in relation to the horizontal line. a. turn the stud counterclockwise to shift beam to the left. See Figure 7-67. Turn vertical headlamp mounting adjuster clockwise to raise beam height. Adjusting head lamps.

Check for brake lamp illumination. 7-50 2002 Buell P3: Electrical .6-3. Disconnect the 6-place tail lamp connector from rear of tail lamp under tail section.18 Screws (2) Lens Bulb 4. Release front brake hand lever. 2. See Figure 7-68. Press rear brake pedal. Tail lamp wire harness connector [7] INSTALLATION NOTE Push up on metal bracket under tail section to align tail lamp mounting holes.2 Nm). Visibility is a major concern for motorcyclists. Attach the 6-place tail lamp connector to the back of the tail lamp. 11WARNING 1WARNING Check for proper tail lamp operation before riding motorcycle. b. REMOVAL 1. 3. Figure 7-68. Turn ignition key switch to IGN. Failure to have proper tail lamp operation could result in death or serious injury. Tighten locknuts to 23-28 in-lbs (2. Locknut (metric) (2) Tail Lamp/Turn Signal Bullet and Blade Connectors 2. Remove two screws and lens. Install new tail lamp bulb by pushing into socket and rotating bulb clockwise. Turn ignition key switch to OFF. c. reread procedure and verify that all steps were performed. Washer (2) a0254x7x 7. Install tail lamp lens with two screws. See Figure 7-68. Tail Lamp 2. d. If operation fails. 3. See Figure 7-68. Squeeze front brake hand lever. Remove two locknuts (metric). See Figure 7-68. Release rear brake pedal. Check for tail lamp illumination. 1. Rotate bulb counterclockwise and pull to remove.HOME TAIL LAMP BULB REPLACEMENT 1. e. Attach tail lamp to tail section with two washers and locknuts (metric). a. washers and tail lamp. Check tail lamp for proper operation. Check for brake lamp illumination.

Figure 7-71. 3. Activate right turn signals using switch on left handlebar. Attach two bullet connectors on turn signal wires as shown in Figure 7-69.26 WINDSCREEN. a0256x7x Left Front Directional Lamp Figure 7-69. washers and windscreen. Rear Turn Signals 2002 Buell P3: Electrical 7-51 Bulb Screw Outer Lens Inner Lens Nut Lockwasher Bullet Connectors (2) . Check turn signals for proper operation. S5 LT. 4. Front bulbs are identical to rear bulbs. See Figure 7-70. Activate left turn signals using switch on left handlebar. If operation fails. 2. 2. Visibility is a major concern for motorcyclists. Remove nut and lockwasher Remove turn signal from headlamp bracket. Failure to have proper turn signal operation could result in death or serious injury. c. See Figure 7-71. See 2. Remove four screws. 2. Remove turn signal from tail lamp bracket. Repeat steps 2-4 for other turn signal. See Figure 7-70. Disconnect two bullet connectors on turn signal wires. See Figure 7-72. See 2. Turn ignition key switch to OFF. Turn ignition key switch to IGN. 3. 5. 4.HOME TURN SIGNALS REMOVAL NOTE Remove screw on back of turn signal to detach lens and install new turn signal bulbs. See Figure 7-69.8-3. 5. Install turn signal with lockwasher and nut. a025x7x Figure 7-70. Repeat steps 2-4 for other turn signal. reread procedure and verify that all steps were performed.2 Nm). washers and windscreen. Remove nut and lockwasher. Front and rear left turn signals must flash. Tighten nut to 25-28 in-lbs (2. 3. b.19 Right Front Directional Lamp R/BK BN BE BK Front 1. Cut cable strap that secures bullet connectors under tail section.26 WINDSCREEN. Nut Bullet Connectors (2) NOTE Install turn signal with lens drain hole facing downward. Headlamp a0255x7x 7. Front Turn Signals 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle. 4. a. Install four screws. Disconnect two bullet connectors on turn signal wires.BE V BE BK 1 HIGH BEAM LOW BEAM LMP GROUND W Y BK 2 3 4 W Y BK S9 [38] S4 Rear 1. d. Front and rear right turn signals must flash. Front Turn Signal Connections Lockwasher Front Turn Signal Assembly INSTALLATION Front 1.

Visibility is a major concern for motorcyclists. See Figure 7-71. Turn ignition key switch to IGN. Use new cable strap to bundle turn signal wires beneath tail section. Insert bullet connectors through rear hole in tail lamp bracket. a. Attach two bullet connectors on turn signal wires as shown in Figure 7-72. d. a0258x7x Right rear directional lamp BN BK LT. To [7] Tail lamp S18 R/Y BK O/W 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle.BE BE NOTE Install turn signal with lens drain hole facing downward. Front and rear left turn signals must flash. c. BK Left rear directional lamp Figure 7-72. reread procedure and verify that all steps were performed. Attach turn signal using lockwasher and nut. Turn ignition key switch to OFF.8-3. Front and rear right turn signals must flash. 2. V R/BK BE 4. b. Failure to have proper turn signal operation could result in death or serious injury. If operation fails. Rear Turn Signal Connections 7-52 2002 Buell P3: Electrical . Tighten nut to 25-28 in-lbs (2.2 Nm). Activate left turn signals using switch on left handlebar. 3. Check turn signals for proper operation. Activate right turn signals using switch on left handlebar.HOME Rear 1.

Failure to have proper turn signal operation could result in death or serious injury.20 Mounting Screw 11WARNING 1WARNING Always disconnect the negative battery cable first. Pry tab on circuit breaker clip left side and remove circuit breaker from clip with wires still attached. 5. 7808 7. Unplug relay connector [30] from flasher relay and remove flasher relay. See Figure 7-73. Turn Signal Flasher Flasher Relay Connector [30] INSTALLATION 1.28 SEAT. Visibility is a major concern for motorcyclists. a. reread procedure and verify that all steps were performed. Replace the unit if it fails. Activate right turn signals using switch on left handlebar. Tighten fastener to 60-96 in-lbs (6. 4. Check turn signals for proper operation. c. Front and rear right turn signals must flash. Disconnect negative battery cable. Turn ignition key switch to OFF. Install seat. 6. 1. Remove seat. 4. See 2. Figure 7-73. See 2. 2. 2. Attach flasher relay to frame tray with screw. Front and rear left turn signals must flash.9 Nm). 11WARNING 1WARNING Check for proper turn signal operation before riding motorcycle. Activate left turn signals using switch on left handlebar. the resulting sparks may cause a battery explosion that could result in death or serious injury. d. 3.28 SEAT. Remove screw and flasher relay from frame tray. 3. Install circuit breaker to clip. If operation fails. b. If the positive cable should contact ground with the negative cable installed.HOME TURN SIGNAL FLASHER REMOVAL NOTE The turn signal flasher is not repairable. Tighten screw to 4-6 ft-lbs (5. 5.8-10. causing loss of control of vehicle and death or serious injury. 11WARNING 1WARNING After installing seat. Connect negative battery cable to battery terminal. Connect relay connector [30] to new turn signal flasher relay. If seat is loose. it could shift during vehicle operation and startle the rider. pull upward on front of seat to be sure it is locked in position.4-8 Nm). See Figure 7-73. Turn ignition key switch to IGN. 2002 Buell P3: Electrical 7-53 .

Cut as many cable straps as necessary to access brake switch connector [170]. Attach throttle cables to hand control. INSTALLATION ACC POWER W/BK1 1 2 o R/Y Right Side 1. See Figure 7-76.8-3. Fasten housings with two screws. 7809 1 2 4. 2. Adjust throttle cables. See 1. Cut cable strap to access right handlebar switch connector [22] behind dash. Right Handlebar Switch [22] IGN POWER BE IGN MODULE W/R FROM [3] GN/BK TO STARTER Y/R 4 3 2 1 GY/O W/BK W/BK BK/R 4. 3. See Figure 7-74. Fasten wiring harness behind dash with new cable straps.21 a0259x7x NOTE The individual handlebar switches are not repairable. Left Side 1. 2. Remove connector [95] from clutch switch. Remove three screws from handlebar switch. 2. Detach connector [22] from wiring harness. Replace switch assembly upon switch failure. Position housings on right handlebar by engaging stud on front housing with hole in handlebar. Right Side 1. Cut cable strap(s) as necessary to access left handlebar switch connector [24] and clutch switch connector [95] behind dash. TO STOPLIGHT R/Y Brake Switch [170] Figure 7-74. See Figure 7-74. Ignition OFF Ignition ON Electric Starter Switch Figure 7-75. Attach connector [170] and connector [22] to wiring harness.18 THROTTLE CABLES.7 Nm). Right Handlebar Switches 7-54 2002 Buell P3: Electrical . Tighten to 25-33 in-lbs (2. 3. Detach connector [24] from wiring harness.HOME HANDLEBAR SWITCHES REMOVAL 7. 3 1. Separate switch housings and remove from handlebar. Route switch housing wiring harness between front forks. 2. Detach throttle cables. 3. Detach connector [170] from wiring harness. Right Handlebar Switch Connection 3.

b.8-3. 2 1 3 4 5 1. reread procedure and verify that all steps were performed.HOME 11WARNING 1WARNING Check all handlebar switch operations before riding motorcycle. Attach connector [24] and connector [95] to wiring harness. Route switch housing wiring harness between front forks. Turn ignition key switch to IGN. 2. Handlebar switches not operating properly could result in death or serious injury. Figure 7-76. If operation fails.7 Nm). a. See Figure 7-76. Attach switch housing to handlebar with three screws. 3. c. Turn ignition key switch to IGN. Turn ignition key switch to OFF. Turn ignition key switch to OFF. Left Handlebar Switch Connection 7079 d. Press passing lamp switch. Handlebar switches not operating properly could result in death or serious injury. Check handlebar switch for proper operation. Tighten screws to 25-33 in-lbs (2. 5. a. Start motorcycle. 3. reread procedure and verify that all steps were performed. a0260x7x Left Handlebar Switch [24] LOW BEAM LIGHT POWER HIGH BEAM HORN FROM FLASHER LEFT TURN RIGHT TURN HORN POWER W BN BK GN BE O LBE GY 1 2 3 5 6 7 8 9 Y BE W Y/BK V/BN V BN O TO GROUND TO STARTER RELAY R/BE BK 1 2 BK TN/GN Left Side 1. c. Set headlamp to LOW beam. Check left and right turn signals. Clutch Switch [95] 11WARNING 1WARNING Check all handlebar switch operations before riding motorcycle. 5. 4. Check handlebar switch for proper operation. b. Fasten wiring harness behind dash with new cable straps. Passing Lamp HIGH Beam LOW Beam Turn Signals Horn Figure 7-77. Check headlamp LOW and HIGH beam settings. Left Handlebar Switches 2002 Buell P3: Electrical 7-55 . e. Headlamp should flash HIGH beam for as long as the switch is pressed. Activate horn by pressing horn switch. If operation fails. f. 2.

a.HOME HORN REMOVAL 1. 2. b. 7079 Figure 7-78. If battery voltage is present. replace left handlebar switch. 3.21 HANDLEBAR SWITCHES. If the horn does not sound or fails to function satisfactorily. test horn grounds and switch using voltmeter. 7-56 2002 Buell P3: Electrical . Y/BK BK 7810 7. If horn is faulty. 3.22 INSTALLATION 1. see TROUBLESHOOTING. Depress horn switch and observe voltmeter reading. d. Figure 7-79. If battery voltage is not present. Turn ignition key switch to IGN. TROUBLESHOOTING 1. Tighten nut to 25-33 in-lbs (2. a. 2. If horn switch is faulty. Remove horn from motorcycle. The horn is not repairable. Loose. b. Connect Y/BK power wire and BK ground wire to terminal clips. c. Horn Switch Location 3. Pull bottom of horn forward slightly and remove nut (metric) from back of horn. See Figure 7-79. Connect voltmeter negative (–) lead to ground. Detach Y/BK power wire and BK ground wire from terminal clips. Check horn operation. c. Press horn switch to activate horn. frayed or damaged wiring leading to horn terminal. Discharged battery. 2. horn or horn grounding is faulty. Horn Switch If battery has a satisfactory charge and wiring appears to be in good condition. See Figure 7-78. Turn ignition key switch to IGN. See Figure 7-78. check for the following conditions: a. a.6-3. Remove Y/BK power and BK ground wires from terminal clips. Attach horn to bracket with nut (metric).7 Nm). either horn switch or wiring to horn is faulty. Horn Assembly Turn ignition key switch to OFF. If horn does not sound or fails to function satisfactorily. b. Connect voltmeter positive (+) lead to Y/BK wire. See 7. See Figure 7-78. b. replace unit as an assembly.

3. Remove switch from right crankcase half (2). Remove transmission sprocket (4) (with secondary drive belt) from main drive gear shaft (3). Install new neutral indicator switch. See 6.HOME NEUTRAL INDICATOR SWITCH GENERAL See Figure 7-80. 4. Apply a light coating of LOCTITE THREADLOCKER 243 (blue) to new neutral indicator switch (1) threads. completing the neutral indicator circuit. Turn nut clockwise to loosen and remove from main drive gear shaft. Remove two socket head screws (7) and lockplate (6). c. 7. Remove transmission sprocket nut (5) from main drive gear shaft (3). 4 5 6 7 3 1. 5. 2. it is immediately forward of the main drive gear shaft (3). Place transmission in first gear. Remove front sprocket cover. there is not enough clearance to allow the removal of the switch without first removing the transmission sprocket.22 SPROCKET COVER. b. 5. The neutral indicator switch (1) is threaded into the transmission portion of the right crankcase half (2). See 2. See Figure 7-80. The sprocket cover must be removed to test the switch. 6. 8. Remove wire lead from neutral indicator switch (1). 9. Tighten to 3-5 ft-lbs (4. Replace the switch if it malfunctions. a0261x7x 6753 7. Connect wire lead to switch. If switch requires replacement. Neutral Indicator Switch REMOVAL/INSTALLATION 1. a. 6. 7. secondary drive belt and transmission sprocket must also be removed.06. Verify that the ignition key switch is turned to OFF. CAUTION Transmission sprocket nut has left-hand threads. 2002 Buell P3: Electrical 7-57 . Install transmission sprocket (4) (with secondary drive belt) onto main drive gear shaft (3).28 INDICATORS.22 SPROCKET COVER.16 TRANSMISSION SPROCKET. Transmission sprocket nut will be damaged if turned counterclockwise to remove. Install sprocket cover. A pin on the shifter drum contacts the neutral indicator switch plunger.23 2 3 1 For diagnostic information. 2. See 2.8 Nm). Neutral Indicator Switch Right Crankcase Half Main Drive Gear Shaft Transmission Sprocket Transmission Sprocket Nut (LH threads) Lockplate Socket Head Screw (2) Figure 7-80. see Section 7. 3. 4. Install switch in crankcase. The switch is not repairable.

Install in the reverse order. The fuse block is on the right side of the frame under the seat. Tighten plastic acorn nuts to 1-3 in-lbs (0. Since the circuit breaker is the automatic-reset type. Lights 15A Key Switch15A System 15A Spare (2) Ignition 7. Disconnect battery negative cable from battery. Tighten screw (if bracket was removed) to 25-27 in-lbs (2. The block contains five replaceable fuses. the bimetallic breaker contacts automatically close (completing the circuit) once they have cooled down from the initial overload. the breaker contacts will again open to interrupt current flow. See 2.HOME FUSES AND CIRCUIT BREAKERS GENERAL Buell motorcycles feature two components which protect the electrical system. Tighten metal nut to 15-18 in-lbs (1. Fuse Block 5 6 Circuit Breakers See Figure 7-82. 4. a0072aox 7.7-2 Nm). Always replace fuses with fuses of the same amp rating.5A Accessory 7. 6. The ignition (5) and accessory (6) fuses are rated at 7. Two spare fuses (4) are attached to the fuse block.1-0. 4 4 3 2 1 1.1 Nm). 2.8-3. 3.28 SEAT. Remove acorn nuts.3 Nm).5A Figure 7-81. This opening and closing of the breaker contacts continues as long as the current circuit overload condition exists. Tag wire leads for ease of assembly. located on left side. 7-58 . Remove circuit breaker from circuit breaker bracket by carefully prying clip tab. 5. Remove fuses by pulling them straight up and out of the fuse block. See your Buell dealer for more information. Always investigate the cause of blown fuses before replacing them. To replace the circuit breaker: Circuit Breaker (30A) 1. If the overload condition still exists. 2.5 amperes.5 BANK ANGLE SENSOR. nuts with lock washers and wire leads from circuit breaker studs. The 30 ampere main circuit breaker is under the seat next to the battery. A broken metal strip indicates a blown fuse. Circuit Breaker 4. See 7. Fuses and Circuit Breakers. The lights (1) key switch (2) and system (3) fuses are each rated at 15 amperes. Remove seat.24 Fuses See Figure 7-81. open and sliding circuit breaker out. 3. 5. NOTE: Bank Angle Sensor will require reinstallation if bracket is removed. Inspect metal strip inside opaque plastic shell. 2002 Buell P3: Electrical 7811 Bracket Tab Figure 7-82.

When the trip switch is pressed again.25 There are seven different diagnostic codes available. all codes are displayed in sequence from d01 to d10.p. check that the problem is not caused by a faulty cable or loose wire connection. The trip odometer mileage will be displayed for 2 to 3 seconds and then the mileage will return to 0 miles. However. is detected. As a code appears in the display (for instance d02). NOTE Make sure no Diagnostic Codes are indicated before reset is held in for more than 5 seconds or diagnostic information will be lost.Speed sensor return shorted low d07 . If the trip switch is pressed for more than 5 seconds at any time while in the diagnostic mode. DIAGNOSTICS Blast Models have a speedometer with self-diagnostic capabilities. T zero the trip odometer. The normal power-up sequence will occur before entering the diagnostic mode. 4. Install bezel inside of rubber boot.Speed output shorted low or open CAL XX .Speedometer application calibration number: 14 = domestic When in the diagnostic mode. press and keep the function switch depressed. Diagnostics cannot be performed if a system voltage is less than 9 VDC or greater than 16 VDC. 5. After all diagnostic codes are displayed. 7. or “toggling” between the odometer and trip odometer displays. the next code will be shown. Install new switch wires using SEALED WIRE SPLICES. The only exception is d08 which is set when the system voltage is greater than 16 VDC.Not used d04 . the odometer will display the first diagnostic code. Reset Switch Replacement 1.Speed sensor return shorted high d06 . have the odometer display visible. When in the diagnostic mode. 2.Not used d08 . Replace the speedometer if the unit is not working properly. 7. it will read “d02SEt” of set or “d02CLr” if clear. Install rubber boot/bezel assembly to odometer reset switch. . They are as follows: d01 . below the starter. the diagnostic code displayed will be erased. Cut wires from switch. The odometer mileage is permanently stored and will not be lost when electrical power is turned off or disconnected.Speed output shorted high d10 . General The reset switch is used to change the odometer display between mileage and trip values and to reset the trip odometer.Speed sensor power output shorted low d02 . The trip odometer can display five numbers for a maximum of 9999. Diagnostic Mode The diagnostic mode is entered by turning the ignition switch from OFF to ON while holding the reset switch in. clear diagnostic codes and exit the diagnostic mode.Speed sensor power output shorted high or open d03 .9 miles. the speedometer calibration number is displayed (CAL14). The function switch allows switching. Remove odometer reset boot from instrument panel. The speed sensor is mounted on the right side of the transmission case. Circuitry in the speedometer also conditions the sensor input to provide an input to the turn signal canceller. The sensor circuitry is that of a Hall-Effect sensor that is triggered by the gear teeth of 5th gear on the transmission main shaft. Unscrew bezel ring from reset switch and pull switch out from behind instrument panel. The diagnostic mode is exited either by turning ignition from ON to OFF to ON again without depressing the reset switch or if a speed signal greater than 5 m.Speedometer power over voltage d09 . 6.9 miles. function switch and the speedometer. The output from the sensor is a series of pulses that are interpreted by speedometer circuitry to control the position of the speedometer needle and the liquid crystal display (LCD) odometer display. 2002 Buell P3: Electrical 7-59 3. It is also used to identify the speedometer calibration and to enter the diagnostic mode.Not used d05 . before replacing a component.h. Diagnostic codes set during this power-up sequence will be stored as well.HOME ELECTRONIC SPEEDOMETER GENERAL The electronic speedometer consists of a speed sensor. The odometer can display seven numbers to indicate a maximum of 999999. Position new reset switch in squared boss Behind instrument panel.

Position dash and speedometer on edge of hard surfaced bench and apply even pressure to dash to open a gap between the speedometer and dash. Unplug connector [20]. Apply LOCTITE THREADLOCKER 243 (Blue) to first few threads of dash panel mounting screws. Lubricate rubber mount with glass cleaner and insert speedometer into dash panel. 6. Speedometer 7748 Figure 7-84. 4. 5. Connector [20] Figure 7-83. 3. Speedometer Fasteners 7749 Figure 7-85. See Figure 7-85. The rubber mount is a tight fit in the dash panel. To remove the speedometer without damaging the dash panel: a. Install speedometer to dash panel with two screws in back of dash panel.HOME REMOVAL 1. See Figure 7-83. Cut and remove cable tie. 4. Remove two screws that secure speedometer to rear of dash panel. Remove two fasteners holding dash panel to upper triple clamp. b. Install connector [39] on back of speedometer. See Figure 7-84. e. Connect connector [20] and replace cable tie to adjacent wire bundle. Speedometer Speed Sensor Dash Panel Screws (2) Connector [39] Rubber Mount a0154x2x Speedometer Screws (2) 30-36 in-lbs (3-4 Nm) Loctite 243 (Blue) Reset Switch Rubber Boot d. 3. 2. Position dash panel in mounting position on upper triple clamp and install two screws. Liberally apply glass cleaner around circumference of rubber mount. c. 2. Apply more glass cleaner in gap and work speedometer free from dash. INSTALLATION 1. Removing Speedometer 7-60 2002 Buell P3: Electrical . Tighten screws to 30-36 in-lbs (3-4 Nm). Depress tab and remove speedometer connector [39]. Loosen screw until head is approximately 1/8 inch above the back surface of the dash.

Speedometer Sensor Screw 11WARNING 1WARNING After installing seat. See 2. Connector is located in the right side frame cavity. 2. Figure 7-86. Locate speed sensor on engine case right side. it could shift during vehicle operation. 4. especially during break-in. See Speedometer Sensor Test in next section. 4. INSPECTION NOTE Debris on speedometer sensor can result in false speedometer reading. Speedometer Sensor 2002 Buell P3: Electrical 7-61 . causing loss of control of vehicle and death or serious injury.28 SEAT.28 SEAT. Always clean and troubleshoot speedometer sensor and verify proper operation before replacing speedometer.HOME SPEEDOMETER SENSOR REMOVAL 1. 7720 7. Speedometer Sensor Connector [65] 7719 INSTALLATION 1. 2. See 2. Install speedometer sensor in engine case. Install seat. to the rear of the starter solenoid.26 3. 3. Remove speed sensor mounting screw. Locate and unplug speedometer sensor 3-place connector [65]. Install screw and tighten to 80-100 in-lbs (9-11 Nm). See Figure 7-86. pull upward on front of seat to be sure it is locked in position. Remove sensor with o-ring from engine case cavity and pull wires down through frame. 5. Connect connector [65] in right side frame cavity. Figure 7-87. Remove seat. See Figure 7-87. Clean any debris from speedometer sensor. If seat is loose.

Enter a frequency from Table 7-3. Press ENTER to begin and reverify.HOME SPEEDOMETER PERFORMANCE CHECK GENERAL See Figure 7-88. NOTE The speedometer should be accurate within 0-4 MPH (06. Test results may be inaccurate if tester battery is low. Attach speedometer tester connector to speedometer sensor connector. Verify that speedometer display reads the corresponding speed. Testing speedometer needle sweeping action. Press ENTER on the tester keypad. 4. 5. HD-41354) cannot be used to verify the calibration of a speedometer and it will not verify the speedometer’s function to support legal proceedings. Place speedometer tester power switch in the ON position. This signal aids in determining whether speedometer replacement is necessary. It can also be used to simulate running engine conditions for ignition system troubleshooting. Speedometer Test Frequency in Hertz (Hz) MARKET 20 MPH (30 KPH) 40 MPH 60 MPH 80 MPH (60 KPH) (100 KPH) (130 KPH) 7-62 2002 Buell P3: Electrical S ca N T n E d R o w n E S ca n S ca C n u p R . It’s purpose is to verify speedometer function when performing service diagnosis or repair. Note that different markets use different frequencies. press CLEAR to cancel and enter the new frequency. b. c. Begin test. a. Table 7-3.5 KPH). These diagnostics may include: ● ● a0262x7x 7. It can also assist in determining if speedometer replacement is necessary. 3. Speedometer Tester ● TESTING NOTE The SPEEDOMETER TESTER (Part No. HD-41354) for speedometer diagnostics. Locate the 3-place Deutsch connector [65] for the speedometer sensor to right of battery and disconnect. Use the SPEEDOMETER TESTER (Part No. 7812 Figure 7-88.27 ST SP H EE D 1 D O TE 3 ER Checking speedometer operation. To change the test frequency. Speedometer Sensor Connector [65] 2. Turn vehicle ignition switch ON. Connector [65] Speedometer Operation Test 1. O P FF O W O E N R H E R T Z P IN O O W U E T R 6 b y M 10 h 0 z 9 b M y1 h z b y M 10 h 0 z 5 b y M 1 h 0 z 2 A LE 8 4 The tester generates a simulated speedometer sensor signal. USA CAN 606 606 1207 1208 1803 1804 2392 2393 Figure 7-89. Place signal switch in the OUT position. NOTES ● b y M 1 h 0 z 7 b M y1 h z 0 Use the following procedures in conjunction with the manual supplied with the speedometer tester. See Figure 7-89.

6 Refer 1. Install the test harness at the speed sensor connector [65]. each 6. a. Press 2 to select LO range (1-20 Hz). clean. See 2. 1 a0263x7x Perform sweep in 3 stages as described in speedometer tester manual. but backlighting and odometer work. 6. Remove sensor and check for debris. 1 To enable diagnostic mode: press odometer reset switch Two Deutsch 3-place socket housings (Part No. install a known. 4.HOME Speedometer Needle Sweep Test The tester’s sweep function moves the speedometer needle through the full range of movement. If testing HI range. Place signal switch in the OUT position. See SPEEDOMETER SENSOR TEST. c. Replace sensor as required. If still non-functional. two system checks must be made. replace sensor and retest. Place speedometer tester power switch in the ON position. Six pin terminals (Part No. 1. Test Harness sor will cause code d02 to set. Six lengths of 18 gauge wire. See 7. If testing LO range. Fabricate a test harness using the following parts. See Figure 7-89. Two secondary locks (pin) (Part No. After selecting a range. Select a test range.000 Hz).26 SPEEDOMETER SENSOR. Deutsch 3-place pin housing (Part No. 7. Press 8 to select HI range (1000-20. 2 To clear codes: depress and hold reset switch for 5 sec- onds with set code displayed. If debris is present. The tester will scan for two seconds. Place speedometer tester power switch in the ON position. 9 Sweep tool has frequency jumps in full scale sweeps. Place signal switch in the IN position. B-41174). a. b. 8 Remove sensor and check for accumulation of debris on sensor. clean sensor and repeat test. Speedometer Sensor Test If the speedometer is inoperative. replace sensor. c. 5. press 1 or 3. then the tester will put out a 1 Hz signal. 72191-94). 72153-94). Before attempting the actual speedometer sensor check. 4. 4 Remove seat. b. ● Test for voltage to sensor by checking for 8-12 VDC on red wire in connector [65B]. 3 To return speedometer to normal operating state: cycle ignition/key switch. then pressing ENTER. Press 5 to select CEN range (21-999 Hz). 6. 2002 Buell P3: Electrical 7-63 . If reading does not change. Then check for continuity to ground on black wire in connector [65B]. Begin test by pressing 0 on the tester keypad. use the corresponding arrow keys to accelerate through the range. 72190-94).0 in. 10 Disconnecting speed sensor or install speedometer sen- Figure 7-90. 72143-94). Rotate the motorcycle’s rear wheel. If testing CEN range. Plug the speedometer tester into the test harness. speedometer sensor is suspect. Raise rear wheel off floor using REAR WHEEL SUPPORT STAND (Part No. Six socket terminals (Part No. Turn vehicle ignition switch ON. b. Press ENTER on the tester keypad. 1. 7211394BK). the speedometer sensor may not be working.27 SPEEDOMETER PERFORMANCE 7 Sensor can also be tested with Speedometer Tester 1 2 (HD-41354) and Test Harness. ● 2. a. check for smooth needle movement. 5. Attach speedometer tester connector to speedometer sensor connector. As you move through the speed range. press 4 or 6. (15 cm) long. Deutsch Socket Housing (2) Deutsch Pin Housing to CHECK. 3. and turn ignition/key switch to ON. speedometer sensor is OK. This allows for testing the smoothness of operation and checking for hesitancy or a stuck needle. press 7 or 9. Two secondary locks (socket) (Part No. 2. Disconnect speedometer sensor connector. Install the test harness between the speedometer sensor connectors [65A] and [65B]. good speedometer sensor and test again for proper operation. if debris is not present. 3. 72103-94BK). 2. See Figure 7-90. If reading on speedometer tester changes as wheel is rotated. See Figure 7-90. 5 Test results may be inaccurate if tester battery is low. Turn vehicle ignition switch ON. ● ● ● ● ● ● ● SPEEDOMETER TROUBLESHOOTING CHART DIAGNOSTIC NOTES: The reference numbers below correlate with those on the diagnostic flow charts found on the following pages.28 SEAT.

6020 Unit OK. 6001 Replace speedometer. Does display toggle between modes? YES NO Replace boot. Toggle switch again and verify operation. 6002 Remove boot over trip reset switch. Toggle trip reset switch without boot. Does display toggle between trip and odometer modes? Replace speedometer. TRIP ODOMETER AND RESET SWITCH TESTING Turn ignition ON. Replace speedometer. Are correct numbers displayed? Loosen reset switch boot and then tighten again until snug. Does display toggle between trip and odometer modes? YES NO YES NO STOP Go to Speedometer Test: Chart 2A. 6020 Figure 7-91. 6020 YES NO Verify trip display consists of correct numbers. 6002 Place jump wire across leads to reset switch on back of speedometer. Does odometer display consist of correct numbers? YES NO Press trip reset switch. Does display toggle between modes? YES NO Replace reset switch.HOME Speedometer Test: Chart 1 ODOMETER. Speedometer Test Chart 1 7-64 2002 Buell P3: Electrical . Return to customer.

Verify that tester battery is OK. Any codes present? If speedometer backlighting is not on. 6008 Go to applicable code in chart (d0x). Recheck for codes.HOME Speedometer Test: Chart 2A INOPERATIVE. Enable diagnostic mode and check for codes. Codes present? Check continuity to ground on BK wire at [39B]. 6008 STOP Go to Speedometer Test: Chart 2B. Proper voltage present? YES NO YES NO Locate and repair open in O/W wire. 3 1 Return speedometer to normal state. Is continuity present? YES NO YES NO Locate and repair open in BK wire. INACCURATE OR ERRATIC SPEEDOMETER Turn ignition ON. 6008 4 5 6 9 10 Hook up speedometer tester. 6004 NO Replace speedometer. Spin back tire. Does speedometer appear to function normally and follow sweeping frequency input? Replace speedometer. Connector or wire damage found? YES Repair as necessary. Speedometer Test Chart 2A 2002 Buell P3: Electrical 7-65 . check for 9-12 VDC on the O/W wire at connector [39B]. Perform speed sweep function and specified speed inputs with tester and observe output speed and odometer/trip meter change on speedometer. 6014 YES Program steady input frequency on tester and observe output speed on speedometer while moving/shaking vehicle harness connections. Is speedometer backlighting on? YES NO 1 2 Enable diagnostic mode and clear codes. Repair connector or harness. Outputs erratic? NO Check 3-pin vehicle speed connector and wires for damage. 6006 YES NO Bad connection found. Turn ignition ON. 6008 Repair harness/ connections. Figure 7-92.

Does voltage fluctuate? YES 6-12 VDC is not present. Voltage present? d01. 6029 NO Replace speedometer. Clean or replace sensor as required. Retest. 6022 Repair wires. 6016 NO 8 Check speedometer speed sensor. Replace speedometer.HOME Speedometer Test: Chart 2B INOPERATIVE. 6022 Repair wires. Problem solved? YES System OK. 6013 8 6-12 VDC is present. d06 7 Check for voltage on W wire in connector [65B]. 6013 YES NO NO d08 Check speedometer power (O/W wire) and ground terminal (BK wire) voltage at back of speedometer. NO 6010 Repair as necessary. Wires OK? YES NO YES NO d05. While connected. 6024 Figure 7-93. meter should read 6-12 VDC when gear tooth absent and 0-1 VDC when gear tooth present. Check for 6-12 VDC on R wire in speedometer sensor connector [65B]. Does it? Check for open wires. Check for wear points on spark plug wire where insulation may be damaged. Test voltage while shaking harness. INACCURATE OR ERRATIC SPEEDOMETER Continued from Speedometer Test: Chart 2A. but no fluctuation to 0-1 VDC. 6013 YES NO Replace speedometer. d02 YES NO Check for continuity to ground on BK wire in connector [65B]. Continuity present? Check for open/ grounded wires. Replace speedometer sensor. Wires OK? Replace speedometer. Speedometer Test Chart 2B 7-66 2002 Buell P3: Electrical . Does damage exist? YES Repair as necessary. 6008 Check for spark plug wire terminal properly seated onto spark plug and secondary coil terminal.

DIAGNOSTICS See diagnostic tables below. Follow the diagnostic flow charts below. 5048 2 High Beam or R/L Turn Signal Indicator Will Not Function Ground Present at Pin 7 of Connector [20A]? YES Is 12V Present when Circuit is Active? NOTE Use Pin 4 (Left Turn). Pin 2 (Right Turn) and Pin 3 (High Beam). If replacement is necessary. Diagnostics 2002 Buell P3: Electrical 7-67 .HOME INDICATORS GENERAL Indicators are Light Emitting Diodes (LEDs) located in the speedometer. 6000 NO Is There Continuity to Ground Through Switch? YES Replace Speedometer.25 ELECTRONIC SPEEDOMETER. NO Locate and Repair Open in Circuit. Replace the speedometer if an LED fails. 1 Oil Pressure or Neutral Indicator Will Not Function Check for 12V at Pin 6 of Connector [20A]. 6000 NO Locate and Repair Open in Circuit.28 Indicator Lights Problem: Light(s) inoperative. 5048 NO Replace Oil Pressure Switch. Is 12V Present? YES Is There Continuity to Ground at Pin 5 (Neutral) and Pin 6 (Oil psi) of Connector [20]? NO Check Fuses or Find Open. 5161 NO Replace Neutral Switch. replace speedometer. LEDs are non-repairable. 5157 Instrument Connector [20] Terminal 1 2 Wire Color Orange/ White Brown White Violet Tan Green/Yellow Black Not Used Red White Black Not Used Power Right Turn High Beam Left Turn Neutral Oil Pressure Right/Left Turn/High Beam Not Used Sensor Power Sensor Return Sensor Ground Not Used Indicator NOTE Oil Pressure Indicator Neutral Indicator High Beam Indicator R/L Turn Indicator Ground Through Switch Ground Through Switch 12V When Active 12V When Active 3 4 5 6 7 8 9 10 11 12 Figure 7-94. 5048 YES Replace Speedometer. See 7. 5048 YES Repair Open in GN/Y Wire (Oil psi) or TN Wire (Neutral). 7.

HOME MAIN WIRING HARNESS GENERAL The main wiring harness runs from the front of the motorcycle (behind dash) to the rear of the frame tray under the seat where it connects to the tail lamp/turn signal mini-harness. 6. 14. Note location of cable tie and cut cable tie on ignition coil and TP Sensor/Auto-Enrichener and Ignition Module harness.16 BATTERY. Remove fuel tank. See 2. See 2. Remove seat. Disconnect right and left handlebar switch connectors [22] and [24]. Disconnect ignition switch connector [33]. See 7. Disconnect ignition connector [10] on left side of frame backbone. Disconnect battery cables. 15. Remove battery.28 SEAT. 7814 Connector [83] 8. 17. Remove windscreen. 7. Disconnect ignition coil connector [83] at coil. the resulting sparks may cause a battery explosion which could result in death or serious injury. 7813 7. Coil Connector [83] a0264x7x Connector [88] 10. Disconnect TP Sensor/Auto-Enrichener connector [88] under frame backbone. 5. Connector [10] 11WARNING 1WARNING To protect against shock and accidental start-up of vehicle. See Figure 7-96. Unhook connector [10] from the T-stud on the left side of the frame backbone.29 REMOVAL 1. Disconnect harness from T-studs. 18. See 4. negative cable first. 9. 4. See Figure 7-95. 2. See Figure 7-97. 3.2 FUEL TANK COVER/FUEL TANK.17 HEADLAMP. Feed harness through frame and upper tie bar mount. 19. disconnect the negative battery cable before proceding. Figure 7-95. 7-68 2002 Buell P3: Electrical Figure 7-97. front brake switch blade connectors [170] and clutch switch connector [95]. 12. If the positive cable should contact ground with the negative cable installed. Tag and disconnect right and left front turn signal bullet connectors.26 WINDSCREEN. 16. Disconnect speedometer connector [39]. Note location of cable tie and cut cable tie on horn wire and remove two blade connectors [122] from horn. Figure 7-96. See 7. Inadequate safety precautions could result in death or serious injury. TP Sensor/Auto-Enrichener Connector [88] Throttle Position Sensor Auto-Enrichener . 13. See Figure 7-95. 11. Disconnect starter connector [128] at starter solenoid. Ignition Connector [10] 11WARNING 1WARNING Always disconnect the negative cable first. Remove headlamp housing and disconnect connector [38]. Note location of cable ties and cut three cable ties on frame backbone that secure main wiring harness to frame.

HOME 20. Figure 7-99. 15. Route wire around oil pump. Connect two blade terminals to stoplight switch above swingarm. Connector [123] Connector [30] 3. Note location. 8. Unplug system relay connector [171] located in frame tray on left side. Disconnect positive (+) wire from battery on circuit breaker (upper stud). Install hose clamp around hoses and oil pressure switch and neutral switch wires. 5. Unplug flasher relay connector [30] and starter relay connector [123] located in frame tray on right hand side. 7819 16. 22. Feed main wiring harness through frame from back to front. See Figure 7-99. 25. Tighten metal nut to 15-18 in-lbs. 2. Disconnect oil pressure switch connector [120]. 21. Disconnect side stand switch connector [60] above swing arm. Mate side stand switch connector [60] located above swingarm. Mate speed sensor connector [65]. Flasher Relay Connector [30] 6. Disconnect speed sensor connector [65] located in frame tray on right side. 28. Tighten plastic acorn nut to 1-3 inlbs (0. Feed wire harness through upper tie bar mount in two bundles. Secure clamp with new locknut. Disconnect Neutral Switch bullet connector [172].1-0. Use two cable ties to secure wires. Disconnect rear brake line switch connector [121] located above swingarm on right side of motorcycle. Connect system relay connector [171] to system relay. 12. Install neutral switch bullet connector [172]. 31. 23. Attach main wiring harness to T-studs. Speed Sensor Connector [65] Positive Wire Flasher Relay Starter Relay INSTALLATION 1. 9. Unhook fuse block. 17. Install starter connector [128] located under starter solenoid. Install oil pressure switch connector [120] to oil pressure switch. and cut two zip ties on wire to frame and wire on voltage regulator mount. Remove nut and clamp that secures oil hoses and wiring harness on right side of motorcycle. 32. Auto-Enrichener 10. 7820 Connector [65] Figure 7-98. Tuck excess harness into right frame pocket. Connect positive (+) wire to circuit breaker. 4. Mate TP Sensor/Auto-Enrichener connector [88] and secure with cable tie. Disconnect voltage regulator wire and wire attached to frame. See Figure 7-99. 26. See Figure 7-100. See Figure 7-99. a0265x7x Connector [88] 7. Install connector [83] to coil and secure with cable tie. 30. 24. Connect flasher relay connector [30] to flasher relay and starter relay connector [123] to starter relay. 14. Cable tie wires. TP Sensor/Auto-Enrichener Connector [88] . Install fuse block. 13. 2002 Buell P3: Electrical 7-69 Throttle Position Sensor Figure 7-100. Feed negative (-) wire across frame and connect to voltage regulator mount and frame. 27. 11. 29. Disconnect tail lamp/turn signal mini harness connector [7] located under seat. Pull main wiring harness out through rear of frame.3 Nm). See Figure 7-98.

Cable tie wires to isolator mount. 31. positive cable first. the resulting sparks could cause a battery explosion which could result in serious injury or death. See Figure 7-95. front brake lamp switch connector [170]. 7815 19. Install seat. Feed longer bundle at front through frame hole to left side of motorcycle. Attach harness to T-stud. turn signals. Mate ignition module connector [10] and attach to T-stud on left side of frame backbone. 27. Secure wires with cable ties. Connect speedometer connector [39]. Hook right side of harness to two T-studs on right side of motorcycle.28 SEAT. 24. turn signal and headlamp operation before riding motorcycle. 29. Install windscreen with four screws and washers. Mate right handlebar switch connector [22].26 WINDSCREEN. 7-70 2002 Buell P3: Electrical . pull upward on front of seat to be sure it is locked in position. 33. 32. Visibility is a major concern for motorcyclists. Cable tie main wiring harness to frame backbone with three cable ties. turn signal and/or headlamp operation could result in death or serious injury. 22. 11WARNING 1WARNING Check for proper tail lamp. See 2. If the positive cable should contact ground with the negative cable installed. causing loss of control which could result in death or serious injury. Secure wires with cable ties. Install left and right front turn signal bullet connectors as marked during removal. Install battery and reconnect battery cables. 20. Connect headlamp connector [38] and install headlamp housing. 4. 28. brake lamp and starting. 30. Mate left handlebar switch connector [24] and clutch switch connector [95]. Horn Connector [122] 11WARNING 1WARNING After installing seat. Figure 7-102. See 2. See 7.17 HEADLAMP.2 FUEL TANK COVER/FUEL TANK. Mate ignition switch connector [33]. 21. 23. 25. Feed horn wires through frame hole on right side and install connector [122] to horn. Y/BK System Relay Figure 7-101.HOME 18. See 7. it could shift during vehicle operation and startle the rider. Failure to have proper tail lamp.16 BATTERY. 26. charging and ignition systems. Check for proper operation of headlamp. See Figure 7-102. System Relay 7816 BK 11WARNING 1WARNING Always connect the positive battery cable first. Install fuel tank. If seat is loose.

HOME 2002 Buell P3: Electrical 7-71 .

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