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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 inflate any tire beyond its maximum inflation pressure as specified on tire sidewall. Overinflation 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 first, 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 muffler 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 muffler 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

0 DOT ● ● ● ● MT designates the rim contour.75 x 16.5 is the width of the bead seat measured in inches. measured at the bead seat diameter.5 x 16. 16.HOME TIRE SPECIFICATIONS GENERAL 11WARNING 1WARNING Tires must be correctly matched to wheel rims. Table 2-1. Rim size and contour are marked on the rim’s exterior surface. Using tires other than those specified can adversely affect motorcycle handling which could result in death or serious injury. See the table below.0 DOT RIM VALVE HOLE DIAMETER 0.5 x 16. Tire Fitment-Tubeless Cast Wheels WHEEL SIZE & POSITION 16 in. 2.33 in. Mismatching tires and rims can cause damage to the tire bead during mounting. 2.2 Tire sizes are molded on the sidewall. Example: MT 2. (8.38 mm) DUNLOP RADIAL TIRE SIZE 100/80 16 K330 120/80 16 K330 2-4 2002 Buell P3: Chassis . (8.33 in. – Front 16 in. DOT means that the rim meets Department of Transportation Federal Motor Vehicle Safety Standards.38 mm) 0.0 is the normal diameter of the rim in inches. – Rear CONTOUR & RIM SIZE MT 2.0 DOT MT 2. Only the tires listed in the fitment table below can be used for replacement.

I.can be 0-9 or X Sample V.3 NOTE Always give the full 17-digit Vehicle Identification Number when ordering parts or making inquiries about your Buell motorcycle.I.Manufactured in East Troy.I. Each vehicle has a 17-digit serial or Vehicle Identification Number (V.) stamped on the steering head.N.) 2002 Buell P3: Chassis 2-5 .HOME VEHICLE IDENTIFICATION NUMBER GENERAL See Figure 2-1. as it appears on the steering head .N.N.KP132500015 Figure 2-1.N. Manufacturer: Buell Motorcycle Company Type Designation: Buell Blast P3 Engine 13 =World 58 =California Horsepower Code Check Digit* Model Year 2002 3 .I.4MZKP13C723500015 Sample abbreviated V. as it appears on the left side crankcase . 2. A Motor Identification Number is stamped on the left side crankcase near the front of the engine. WI Sequential Number 500001-520000 = World 520001-525000 = CA 4 MZ KP 13 C 7 2 * 500015 **Varies . Vehicle Identification Numbers (V.

Wheel Service CHECK FOR Loose axle nuts. See 2. 2-6 2002 Buell P3: Chassis . Regularly inspect wheels and tires for damage and wear. Replace as described under 2. TROUBLESHOOTING See Figure 2-2. (2. Alignment of rear wheel in frame or with front wheel. Overinflation may lead to premature tire failure which could result in death or serious injury. (2. Rims and tires out-of-round or eccentric with hub. Check for leaks. Shock absorber. See 2. see Table 2-2. Inflate tires to correct pressure.19 SWINGARM. Irregular or peaked front tire wear. Rims and tires out-of-true sideways.090 in. See 2. However. See 2.2 TIRE SPECIFICATIONS. Checking Tire Inflation Pressure Table 2-2.18 FORK STEM AND BRACKET ASSEMBLY. Check tire inflation pressure at least once each week. Steering head bearings. Check damping action and mounts. Replace rims. dynamic balancing is strongly recommended. Check for looseness.17 FRONT FORK.HOME WHEELS GENERAL Good handling and maximum tire mileage are directly related to the care of wheels and tires. Repair swingarm as described under 2. Swingarm bearings. Tighten rear axle nut (metric) to 48-52 ft-lbs (65-71 Nm). a0198x2x 2.9 TIRES. Excessive side-play or radial (up-and-down) play in wheel hubs. Replace wheel hub bearings. Correct tire inflation. cuts. At the same time. See 2.15 REAR SHOCK ABSORBER.5 FRONT WHEEL or 2. Repeat the inspection before long trips. Keep tires inflated to the recommended air pressure. breaks and other damage. Replace rims.080 in. should not be more than 0. Damper tubes. See 2.9 TIRES. Always balance the wheel after replacing a tire.03 mm). inspect tire tread for punctures. REMEDY Apply LOCTITE THREADLOCKER 243 (Blue) and tighten front axle nut (metric) to 38-42 ft-lbs (52-57 Nm).19 SWINGARM. See 2. Figure 2-2. should not be more than 0.4 11WARNING 1WARNING Do not inflate any tire beyond its maximum inflation pressure as specified on tire sidewall. Correct tire and wheel balance. Static balance may be satisfactory if dynamic balancing facilities are not available. If handling problems occur.29 mm).9 TIRES. Correct adjustment and replace pitted or worn bearings.

Failure to comply with the guidelines below could result in death or serious injury. 4. Speed should not exceed 50 mph (80 km/h) for the first 24 hours after repair and the repaired tire should NEVER be used over 80 mph (128 km/h). See Table 2-2. Failure to follow this warning could result in death or serious injury. At regular intervals of 5000 miles (8000 km) or whenever handling irregularities are noted. Always locate and eliminate the cause of the original tire failure. Buell recommends that you see your dealer for these services. 3. 2002 Buell P3: Chassis 2-7 . 11WARNING 1WARNING Buell recommends replacement of any tire punctured or damaged. Other tires may not fit correctly and may be hazardous to use. 2. These procedures weaken the casing and increase the risk of a blowout. Since the servicing of these components requires special tools and skills. Do not patch or vulcanize a tire casing. Tires and wheels are critical items. same as original equipment tires must be used. If tires must be replaced. 1. if a temporary repair is made. which could result in death or serious injury. 11WARNING 1WARNING Excessively worn tires adversely affect motorcycle traction. ride slowly with as light of a load as possible until the tire is permanently repaired or replaced. Do not use tires other than those specified. steering and handling. In some cases small punctures in the tread area may be repaired from within the demounted tire by your Buell dealer.HOME 11WARNING 1WARNING Use the following guidelines when installing a new tire or repairing a flat. perform the recommended service checks. In emergency situations.

5 7 1 2 6 5 3 See Figure 2-3. Inspect all parts for damage or excessive wear. 6. 3. Reseating pistons requires caliper disassembly. 7. See Figure 2-4. 2002 Buell P3: Chassis 1. Raise front wheel off floor. 1 4 5 2 11WARNING 1WARNING Always replace brake pads in complete sets for correct brake operation. a. Remove five bolts (10) and washers (11) to detach front brake rotor (12) from wheel hub. See Figure 2-6. Never replace just one brake pad. 2-8 Inspect brake rotor and pads. Remove brake pads. a. See Figure 2-5. 3. Remove brake pads from caliper. Insert screwdriver/rod through axle hole (1). 5. 3 CLEANING AND INSPECTION 1. Figure 2-3. NOTE 4 1. 6.7 SEALED WHEEL BEARINGS. Remove upper mounting screw (5) and brakeline wireform (7) while supporting caliper above brake rotor. Inspect wheel bearing end play and service bearings if necessary. b. Failure to install brake pads as a set could result in death or serious injury. 2. See Figure 2-3. 3. 2. Loosen front axle nut (4). b. Front Wheel Mounting . Washer Axle Nut (metric) Spacer (and washer) Figure 2-5. Discard washers. Remove tire. 2. Axle Hole Pinch Screw 3. Front Brake Caliper Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. 7. See 2. Remove pad hanger pin (metric). 5. 8273 2. Detach caliper from mounts. 7702 Pad Spring DISASSEMBLY 1. Remove pin plug (4). 7734 Pad Hanger Pin Figure 2-4. Thoroughly clean all parts in solvent. Remove front axle nut. 5. Pull front axle out of wheel hub while supporting front wheel.9 TIRES. 2. Brake Line Banjo Bolt (metric) Banjo Washers (2) 4. c. spacer and washer. 4. 4. See 2. Pad Spring 2. Remove lower mounting screw (5). Remove caliper by tilting away from wheel and then pulling away from rotor. Loosen pinch screw (2). Pin Plug Mounting Screws (2) Bleeder Valve Wireform c.HOME FRONT WHEEL REMOVAL 1.

4. 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 4 11 10 8 7 6 5 9 12 Figure 2-6. 2. 8. 5.HOME 1. 11. 3. 7. 6. 13. Front Wheel Assembly 2002 Buell P3: Chassis 2-9 . 12. 9. 10.

b.HOME ASSEMBLY 11WARNING 1WARNING Do not allow brake fluid. 1. Verify that the front brake rotor is thoroughly clean. tighten axle nut (1) (metric) to 38-42 ft-lbs (52-57 Nm). 2. Tighten TORX screws (10) with NEW washers (11) in criss-cross pattern to 24-27 ft-lbs (33-37 Nm). With pinch screw (metric) loose. 5. 3. See Figure 2-6. 2. Tighten the front axle pinch screw to 13-16 ft-lbs (1822 Nm). Install front brake rotor (12) on right side of wheel. bearing grease. NOTE Do NOT reuse brake rotor mounting washers (11).8 CHECKING CAST RIM RUNOUT. a. c. Insert screwdriver or steel rod through hole in axle. Install axle nut (1) (metric) over threaded end of axle. Verify that wheel and tire are true. Balance tire. Compress the front suspension to make sure it is free and not binding. Apply LOCTITE THREADLOCKER 272 (red) to threads of each of the five T40 TORX screws (10). b. c. Apply LOCTITE THREADLOCKER 243 (blue) to axle threads. INSTALLATION 1. See 2.9 TIRES. While holding axle stationary. Position wheel between forks with brake rotor on gearcase side of motor. Install axle nut. insert threaded end of axle through right side fork. c. a. if removed. Push axle through fork and wheel hub until axle begins to emerge from left side of hub. 4. 3. a. d. See 2. Install front brake caliper. See 2. Install rotor (12) on wheel hub.11 FRONT BRAKE CALIPER.9 TIRES. Always use new washers (P/N CB0004. See 2. 2-10 2002 Buell P3: Chassis . d. Install axle spacer (2) and washer (13). Adjustment. See Figure 2-6. Install tire. Install front axle.T) when assembling wheel. b. or other lubricants to contact brake rotor or brake pads or reduced braking ability may occur which could result in death or serious injury. 4.

Raise rear wheel off floor using REAR WHEEL SUPPORT STAND (Part No. Place rod or screwdriver through axle hole. 4.HOME REAR WHEEL REMOVAL 1. Spacer Sprocket Bolts (5) Sprocket Cover Inspect tire. Rear Axle. Drive sprocket failure could lead to loss of control of vehicle which could result in death or serious injury. 6. 2002 Buell P3: Chassis 2-11 . See Figure 2-7. Remove sprocket from rear wheel. Position sprocket on rim with holes in sprocket and rim aligned. Inspect all parts for damage or excessive wear. 3.8 SEALED WHEEL BEARINGS. Remove nut. See 2. 11WARNING 1WARNING Use only new P/N BA0511. See 2. and flat washer. 1. 6. 2. 8. 4.9 TIRES. 5. 1. 6 3 4 5 2 CLEANING AND INSPECTION 1. Remove right side spacer. 1 6 7 Axle Axle Nut (metric) Lockwasher Washer 5. Remove left side spacer. a. 7. Thoroughly clean all parts in solvent. Remove and discard five sprocket bolts (6) from sprocket cover. Pull axle out.5 mm. 1. 4. 7747 2. 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. 7701 1 4 2 DISASSEMBLY Remove and discard hardened washers from sprocket. Lay wheel on clean work area with rotor side down.2Z hardened washers between sprocket cover and sprocket. 3. Loosen rear axle nut (1) (metric).14 REAR BRAKE CALIPER. ASSEMBLY Figure 2-8. Replace if less than 4. 7. See Figure 2-8. 3. Move wheel forward and slide belt off. 2. 4. Right Side 11WARNING 1WARNING Do not allow brake fluid. 2. See 2. Slide carrier with caliper off rotor. Remove five T40 TORX screws and brake rotor from rear wheel. Replace if warped or badly scored. 2. Inspect brake rotor. 2. Reseating piston requires caliper disassembly. b. Failure to use hardened washers could cause sprocket to fail. Inspect wheel bearing end play and service bearings if necessary. Remove sprocket cover (7) from sprocket. Measure rotor thickness. 4. Rear Wheel Mounting 1.6 3 NOTE Do not operate rear brake pedal with rear wheel removed or caliper piston may be forced out. Axle Nut (metric) Lockwasher Washer Axle Hole Figure 2-7. Check rotor surface. 3. 3. B-41174). 2. 5. lockwasher.

12. 3. 5. 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. 7. 4. Verify that the brake rotor is thoroughly clean. Install brake rotor (9) to wheel. Apply LOCTITE THREADLOCKER 272 (red) to threads of each of the five T40 TORX screws (8). Position sprocket cover over washers and install to sprocket with five new sprocket bolts. Nut (metric) Left Axle Spacer Wheel Bearing (Left side) Wheel Axle Spacer. Install rotor (9) on wheel hub. 11. 9. 4. 2. a. a0079x2x 8 2 3 5 11 7 9 6 12 11 1. Tighten TORX screws in criss-cross pattern to 24-27 ft-lbs (33-37 Nm). Place new hardened washers on sprocket. 6. 5. c. Tighten sprocket bolts to 18-22 ft-lbs (24-30 Nm). Rear Wheel Assembly 2-12 2002 Buell P3: Chassis . See Figure 2-9. 10. 8.HOME 3. b.

a. Insert axle through right side spacer and swingarm. 4. Hold left side spacer in place and slide caliper and carrier over rotor. 3. 6. 4. 7705 NOTE Do not place belt on sprocket teeth at this time. c. 2. 3. 5. See Figure 2-11. Rear Axle. Slide belt on sprocket teeth by rotating wheel to “walk” belt onto teeth. Resting belt next to teeth allows slack for easier alignment of wheel assembly. Right Side 2002 Buell P3: Chassis 2-13 . lockwasher and axle nut. Place wheel centrally in the swingarm. swing arm. 5. 1. carrier. Axle Axle Nut (metric) Lockwasher Washer Spacer Sprocket Bolts (5) Sprocket Cover Figure 2-11. 6. Alignment of parts will be difficult. Slide wheel far enough forward to slip belt over sprocket and rest belt on sprocket inboard of the teeth.HOME INSTALLATION 1. Axle Rear Axle Hole 2 1 Place screwdriver or rod through axle hole and torque rear axle nut to 48-52 ft-lbs (65-71 Nm). Slide axle through washer. 7. 2. Install flat washer. Hold right side spacer in place. Left Side 7701 6 3 4 5 2 1 6 7 1. Lower motorcycle rear wheel. Rear Axle. Figure 2-10. 2. b. left side spacer and wheel assembly. See Figure 2-10.

002 in. Install nut (2). Block motorcycle underneath frame so wheel is raised off the ground. 2. See Figure 2-14.7 3.HOME SEALED WHEEL BEARINGS INSPECTION 1. Removal Tool b. Remove Bearing 2-14 2002 Buell P3: Chassis . 2. washer (3) and Nice bearing (4) on screw. a. If the end play is less than the service wear limit of 0. Sparingly apply graphite lubricant to threads of forcing screw (1) to prolong service life and ensure smooth operation. 5. c. Mount a magnetic base dial indicator to the brake disc with the dial’s contact point on the end of the axle. Hold end of forcing screw (1) and turn collet (6) to expand edges of collet. If the end play exceeds service wear limit or feels rough. Figure 2-12. Repeat procedure for opposite side bearing. 6 Forcing Screw Nut Washer Nice Bearing Bridge Collet with Ball Bearing inside Figure 2-13. B-43933 1. Fasten collet and ball bearing to forcing screw (1). bearing passes inspection. 3. 3. 4. 6. 6. 2 1. 2. 1 REMOVAL 3 PART NO. See Figure 2-13. Drop ball bearing inside collet (6). 4. Obtain WHEEL BEARING INSTALLER/ REMOVER (Part No. 1. b. Turn the wheel through several rotations. remove wheel and replace both wheel bearings. then move the wheel side to side to check for lateral end play. See Figure 2-12. 2. HD-44060) and assemble. Discard all bearings upon removal. Forcing Screw Nut Figure 2-14.051 mm). When expanded collet has gripped bearing edges. a. Insert assembly through hole in bridge (5). Wheel Bearing Inspection (Front Wheel Shown) a0200x2x a0199x2x 2. SPECIALTY TOOL Wheel bearing installer/remover 2 4 5 Remove wheel from motorcycle. hold end of forcing screw (1) and turn the nut (2) to remove bearing from wheel. (0. Remove spacer from inside wheel hub. a020x2x 1 5.

2. 3. 1 1. 1. Installation Tool Support Plate b. Pilot. Remove tool.HOME INSTALLATION PART NO. Reverse tool and install opposite side bearing. washer (3) and nut (2) over rod. Install pilot (5). Install spacer sleeve inside wheel hub. 4. If front wheel has two brake discs. 6. Pilot. Parts 10-13 used for installation only. c. a0203x2x 5 4 6 Hold hex end of threaded rod (1) and turn nut (2) to install bearing (6). Wheel bearing installer/remover. See Figure 2-15. Place the new bearing (6) on rod (1) with lettered side outward. B-43933) and assemble. B-43933 SPECIALTY TOOL See Figure 2-17. Sparingly apply graphite lubricant to threads of threaded rod to prolong service life and ensure smooth operation. Parts 8-9 used for removal only. Support Plate Threaded Rod PART NO. Obtain WHEEL BEARING INSTALLER/REMOVER (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. a. d. DESCRIPTION Bridge Steel Ball Forcing Screw Nut Washer Nice Bearing Lubricant Collet. Insert assembly through wheel. 4. Bearing will be fully seated when nut can no longer be turned. Threaded Rod Nut Washer Nice Bearing Pilot Wheel Bearing 3 2 Figure 2-16. install bearing on the left side first. 7 8 5 13 9 10 11 12 13 Figure 2-17. 3/4 in. B-43933) 2002 Buell P3: Chassis 2-15 . 5. Installing Bearing a0204x2x 8 6 7 9 NO. Place threaded rod through support plate.0 in. 1. Wheel Bearing Remover/Installer (Part No. 3/4 in. a0202x2x NOTE Always install first bearing on primary brake disc side. Nice bearing (4).0 in. 3. Figure 2-15. 1. Collet. 2. See Figure 2-16.

(1.8 Wheel Truing and Balancing Stand (Part No. Tighten arbor nuts so hub will turn on its bearings.76 mm) Wheel Truing and Balancing Stand (Part No. Replace wheel if runout exceeds specification shown in Table 2-3.02 mm) MAXIMUM RADIAL RUNOUT 0. 2. HD-99500-80). See Figure 2-18. 3. HD-99500-80) Rim Lateral Runout 1. HD-99500-80). Table 2-3. Check radial runout as shown. Replace wheel if lateral runout exceeds specification shown in Table 2-3. Check rim lateral runout by placing a gauge rod or dial indicator near the rim bead. HD-99500-80) Gauge Rod Figure 2-19. Rim Radial Runout 1. Tighten arbor nuts so hub will turn on its bearings. Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND (Part No. Checking Cast Rim Radial Runout 2-16 2002 Buell P3: Chassis . 3. Wheel Runout a0206x2x WHEEL TYPE Cast MAXIMUM LATERAL RUNOUT 0. Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND (Part No.HOME CHECKING CAST RIM RUNOUT GENERAL Check wheels for lateral and radial runout before installing a new tire. See Figure 2-19. Checking Cast Rim Lateral Runout Gauge Rod 2. (0.040 in. Figure 2-18. a0205x2x 2.030 in.

HD-01289) to the rim. . Use front tire ONLY for a front tire. Installing a tire with the wrong rotation may lead to tire failure which could result in death or serious injury. Remove valve stem if it is damaged or leaks. 3. See 2. 4. HD-21000) for inspection and repair procedures. Remove tire from rim. start upper bead over edge of rim at valve. See 2. Repeat all around rim until first bead is over rim. Mount tire on TIRE SPREADER (Part No.6 REAR WHEEL. 5. Failure to follow this warning could result in death or serious injury. Pry bead over rim edge. Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury. Loosen both tire beads from rim flange. a0208x2x Pry bead over rim edge and remove tire from rim 11WARNING 1WARNING Do not use excessive force when starting bead over rim. Some tires require different tire rotation depending on whether tire is used on front or rear wheel. Some tires have arrows molded into the tire sidewall. See Figure 2-21. Replace worn tires. Starting Tire Off Rim (Typical) 6. Inspect tire for wear and damage. 2. Push lower bead into rim well on one side and insert tire tool underneath bead from opposite side. 8. Using tire tools (not sharp instruments). breaks and wear at least weekly. The red circle on the sidewall is a balance mark and should be located next to the valve stem hole. 11WARNING 1WARNING Always check both tire sidewalls for arrows indicating forward rotation. Clean inside of tire.HOME TIRES GENERAL Inspect tires for punctures. cuts. DO NOT put a rear tire on the front of a vehicle. 2. These tires should be mounted on the rim with the arrow pointing in the direction of forward rotation. If rim is dirty or corroded. See Figure 2-20.9 CLEANING AND INSPECTION 1. 3. Loosening Beads from Rim Flange (Typical) REMOVAL 1. They are not interchangeable. If a bead breaker machine is not available. Deflate tire. Rear wheel only: Remove rear sprocket. 7. attach RIM PROTECTORS (Part No. 2. Remove wheel from motorcycle.5 FRONT WHEEL or 2.6 REAR WHEEL (Disassembly). clean with a stiff wire brush. A bead breaker machine simplifies tire removal Figure 2-20. 2002 Buell P3: Chassis 2-17 Figure 2-21. a0207x2x 11WARNING 1WARNING Dunlop front and rear tires for Buell motorcycles are not the same.

11WARNING 1WARNING Aftermarket valve caps that are heavier than the stock cap may have clearance at slow speeds. Apply air to stem to seat beads on rim. 3. Install tire and check tire tread radial runout again. 4. Replace rims not meeting specifications.7-5. 4. (2.080 in. Rapid tire deflation could cause loss of control which could result in death or serious injury. See Figure 2-22. work bead on as far as possible by hand. Thoroughly lubricate rim flanges and both beads of tire with tire lubricant. Starting Bead on Rim (Typical) a0209x2x Lubricate rim flange and both beads before installation 2. Use a tire tool to pry the remaining bead over rim flange.03 mm). 4. remove tire from rim.060 in. Checking Tire Radial Runout 2-18 . Inflating 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.060 in.03 mm) maximum 11WARNING 1WARNING Do not inflate over 40 psi (276 kPa) to seat the beads. Work bead onto rim with tire tools. Damaged or leaking valve stems must be replaced. Checking Tire Lateral Runout Checking Tire Lateral Runout 1. at high speed the valve/cap will be moved outward by centrifugal force. See 2. Check rim bead side runout. Starting at the valve stem.52 mm). start first bead into the rim well using a bead breaker machine. (1. See 2. damage the valve and cause rapid tire deflation. damage the valve and cause rapid tire deflation. See Figure 2-23. Tire radial runout 0. Install tire and check again for tire tread lateral runout. (2. 6. Tire tread lateral runout should be no more than 0. Tire tread radial runout should not be greater than 0. Check rim bead runout. Figure 2-22. Gauge Figure 2-24. If no machine is available.8 CHECKING CAST RIM RUNOUT. Install and tighten nut to 42-44 in-lbs (4. Tire lateral runout 0. 2002 Buell P3: Chassis a0211x2x 2.080 in. a0210x2x 5. If runout is more than 0. (2. Turn wheel on axle and measure tread radial runout. Place rubber grommet on valve stem with shoulder in recess of the valve stem head. remove tire from rim. Gauge Figure 2-23.8 CHECKING CAST RIM RUNOUT. working toward valve in both directions.52 mm) maximum 3. 1. Checking Tire Radial Runout 1. HD28700) on the tire until beads seal on rim.03 mm). 2. Start 180° from valve stem hole and place second bead on rim. This outward movement could cause the valve/cap to strike the adjacent components. 3.080 in.0 Nm). A valve or valve and cap combination that is too long may interfere with (strike) adjacent components. See Figure 2-24. It may be necessary to use a TIRE BEAD EXPANDER (Part No.HOME INSTALLATION 11WARNING 1WARNING Only install original equipment (stock) tire valves and valve caps. Replace rims not meeting specifications. (1. but. If runout exceeds specification. Turn wheel on axle and measure amount of displacement from a fixed point to tire sidewall. Rapid tire deflation could cause loss of control which could result in death or serious injury.

See Figure 2-25.0 oz. 5. dynamic balancing. HD-99500-80) will produce satisfactory results. Follow the instructions supplied with the balance machine you are using. apply three drops of LOCTITE SUPERBONDER 420 to adhesive side of weight. However. Press weight firmly in place and hold for ten seconds.0 oz. static balancing using WHEEL TRUING AND BALANCING STAND (Part No. (7 g) at 60 MPH (97 KM/H). (56 g) total weight applied to the rear wheel. For additional adhesive strength. Use only WHEEL WEIGHTS (Part No. dry and free of oil and grease. 43692-94Y) which have special self-adhesive backings. can be used to produce finer tolerances for better high-speed handling characteristics. utilizing a wheel spinner. Wheel Weights (Typical) 3. especially at high road speeds. Apply WHEEL WEIGHTS to the flat surface of the wheel rim. Remove paper backing from weight. Make sure that area of application is completely clean. 2002 Buell P3: Chassis 2-19 . 2. (28 g) total weight applied to the front wheel. Place weight on flat surface of wheel rim. In most cases.HOME ADJUSTMENT Wheel Balancing Wheel balancing is recommended to improve handling and reduce vibration. Figure 2-25. 4. Allow eight hours for adhesive to cure completely before using wheel. a0212x2x Wheels should be balanced to within 1/4 oz. 1. 2. WEIGHTS FOR CAST WHEELS The maximum weight permissible to accomplish balance is: ● ● 1.

2. Prevent damage to seating surfaces by carefully removing brake line components. b. 5. 1. Remove two screws (1) (metric) and clamp (2) to detach master cylinder assembly from handlebar.HOME FRONT BRAKE MASTER CYLINDER REMOVAL NOTE Do not remove the master cylinder unless problems are being experienced. Install a length of plastic tubing over caliper bleeder valve. c. 2. Draining Front Brake System a0213x2x 1 2 3 5 4. 3. a. CAUTION Damaged banjo bolt seating surfaces will leak when reassembled. Figure 2-26. Discard used fluid according to local laws. Clamp Screws (2) (metric) Clamp Master Cylinder Cover Screws (2) Banjo Washers (2) Brake Line Banjo Bolt (metric) Figure 2-27. Remove banjo bolt (6) (metric) and two banjo washers (4) to disconnect brake line (5) from master cylinder. 4. See Figure 2-27. 3. 4 6 1. See Figure 2-26. Drain brake fluid into a suitable container. Replace switch upon failure. Unplug both terminals to detach brake lamp switch. d. Place free end in a suitable container. Tighten bleeder valve to 3-5 ft-lbs (4-7 Nm) 8273 2. 5. Pump brake hand lever to drain brake fluid. NOTE The individual parts of the brake lamp switch are not serviceable. 6. Open bleeder valve (metric) about 1/2-turn. Discard banjo washers. Front Master Cylinder 2-20 2002 Buell P3: Chassis .10 Bleeder Valve (metric) Remove mirror from right handlebar.

See Figure 2-30. Lockwasher and Washer Tang Front Brake Switch 1 2. Remove screw. Replace as necessary. 2. See Figure 2-31. pitting or corrosion. 3. Boot Piston Snap Ring Figure 2-30. 3. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. dents or other damage is noted.HOME DISASSEMBLY 1. Remove piston assembly (1-4) from front master cylinder. 1. 5. Replace housing if any of these conditions are found. 3.O. 2. lockwasher and washer (1) holding front brake switch (3) to master cylinder assembly. Depress piston assembly and remove internal snap ring (3). 2. 3 2 1. Compress piston (2) and remove rubber boot (1). Inspect boot for cuts. such as gasoline or paint thinner. Remove pivot bolt (2) from lever pivot. 6488 2 3 Detach front brake hand lever (3) from master cylinder assembly. Discard snap ring. 3. 3. 1 2 5. Figure 2-29. 1. Inspect outlet port that mates with brake line fitting. replace housing if any scratches. tears or general deterioration. Front Brake Switch 6490 4. Hand Lever 1 4. lint free cloth. Do not use a wire or similar instrument to clean drilled passages in bottom of reservoir. Do not use mineral-base cleaning solvents. Snap Ring 2002 Buell P3: Chassis 2-21 . Inspect piston bore in master cylinder housing for scoring. See Figure 2-28. b. Wipe dry with a clean. 4 BRAKE FLUID. Screw. CLEANING AND INSPECTION 6489 11WARNING 1WARNING Clean brake system components using denatured alcohol. Detach front brake hand lever. This could result in improper brake operation which could result in death or serious injury. See Figure 2-29. a. As a critical sealing surface. 3 1. Carefully inspect all parts for wear or damage and replace as necessary. Blow out drilled passages and bore with a clean air supply. Do not contaminate with mineral oil or other solvents. Remove switch. Clean all parts with denatured alcohol or D.T. Remove nut (1) (metric) from lever pivot. 6. Nut (metric) Pivot Bolt Hand Lever Figure 2-28. 2.

T. See Figure 2-27. Secondary cup (3) sits within ridge at middle of piston (4). hydraulic brake line and master cylinder bore are completely clean. Remove the two master cylinder cover screws (3). a. Connectors 11WARNING 1WARNING Use only new black banjo washers (See Parts Catalog for Part No. 4 BRAKE FLUID. b. See Figure 2-28. Tighten to 4-13 in-lbs (0. Attach front brake switch with screw. spring first. INSTALLATION 1. 6491 1 2 3 4 5 Insert piston assembly. Tighten to 80-120 in-lbs (9-14 Nm). washer and lockwasher (1). Install front brake hand lever. Piston Assembly 5. See Figure 2-27.O. Fasten master cylinder to handlebar by installing clamp (2) and screws (1) (metric). b. Secure with a new snap ring (6). 2. See Figure 2-27.8-1. a. 3. 2. d.HOME ASSEMBLY 1. Earlier silver banjo washers are not compatible with D. c. Verify brake lamp switches are secure. 6569 6 1. See Figure 2-32. Install ridge on boot (5) into groove on piston (4). 4. Lubricate pivot bolt (2) with LOCTITE ANTI-SEIZE. Small end of spring (1) sits behind primary cup (2).5 Nm). 5. b. 4 fluid and will not seal properly over time. 4 brake fluid. Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury. Install mirror parallel to handlebars. 6.5 Nm).T. (3. banjo bolt. Tighten to 7-13 in-lbs (0. ensure that banjo washers. Install pivot bolt through top of assembly.125 in. Spring Primary Cup Secondary Cup Piston Boot Snap Ring Figure 2-31. With the master cylinder in a level position. Attach wires to switches. Connect brake line (5) to master cylinder using two new banjo washers (4) and banjo bolt (6) (metric). 2. a. into master cylinder. 4. Brake Lamp Switch Connectors a0214x2x Brake Fluid Level 3. Large side of primary cup faces spring. Install nut (1) (metric).T. Tighten to 16-20 ft-lbs (22-27 Nm). 4. 3. Figure 2-33. Bring fluid level to within 0. Align hole in lever (3) with hole in master cylinder assembly. 5. 2002 Buell P3: Chassis Figure 2-32. CAUTION To avoid leakage.O.) with D. Brake Fluid Level 2-22 . Tang (3) on switch must release when hand lever (2) is moved. See Figure 2-31. Tighten to 44-62 in-lbs (57 Nm). 6. add D. cover and cover gasket. Install front brake lamp switch (7). Check piston assembly components.2 mm) of molded boss inside front master cylinder reservoir. See Figure 2-33.O. Test switch action.5-1.

10. See Figure 2-34. or braking efficiency is poor. Verify proper operation of the master cylinder relief port. Bleed brake system. A plugged or covered relief port can cause brake drag or lockup.6 BRAKE SYSTEM MAINTENANCE. Lockwasher and Washer Hand Lever Tang Figure 2-35. Actuate the brake lever with the reservoir cover removed. Testing Hand Lever 2002 Buell P3: Chassis 2-23 . 3. See 1.0-1. Visibility is a major concern for motorcyclists. Apply brake hand lever to test brake lamp operation. 2. 11. Tighten to 9-13 inlbs (1. See Figure 2-35. 1. 8. Turn ignition switch to LOCK. Figure 2-34. Verify proper operation of the master cylinder relief port. Failure to have proper brake lamp operation could result in death or serious injury. See Figure 2-27. A slight spurt of fluid will break the surface if all internal components are working properly. which could result in loss of vehicle control and death or serious injury 7.5 Nm).HOME 11WARNING 1WARNING 6492 See Figure 2-34. Attach master cylinder cover and cover gasket with the two cover screws (3). Outlet Port 9. testing at high speeds could result in death or serious injury. 1 11WARNING 1WARNING Always test motorcycle brakes at low speed after servicing or bleeding system. If brakes are not operating properly. Turn ignition key switch to IGN. Master Cylinder Body 11WARNING 1WARNING 6493 Check for proper brake lamp operation before riding motorcycle. 2 3 Screw.

Remove piston outer seals (4) and inner seals (2) from their respective grooves in caliper. Front Brake Caliper 2-24 2002 Buell P3: Chassis . Detach caliper from mounts.HOME FRONT BRAKE CALIPER REMOVAL NOTE Steps 1 and 2 are not required for detaching caliper from rotor. 8273 2. Prevent damage to seating surfaces by carefully removing brake line components. See Figure 2-36. a. Drain and discard brake fluid. 4. Wipe dry with a clean. Remove brake pads. 7. Use BRAKE CALIPER PISTON REMOVER (Part No. Remove brake pads from caliper. b. lint free cloth. 3. 7 1 2 6 5 c. Blow out drilled passages and bore with a clean air supply. b. 1. Remove banjo bolt (2) (metric) and two banjo washers (3) to disconnect brake line (1) from caliper. 5. 3. This could result in improper brake operation which could result in death or serious injury.O. DISASSEMBLY 1. See Figure 2-38. a. d. 2. Do not use a wire or similar instrument to clean drilled passages. Do not use mineral-base cleaning solvents. Remove pin plug (4). Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. B-42887) to pull the two pistons from caliper bores. c. 3 4 Brake Line Banjo Bolt (metric) Banjo Washers (2) 4.T. CAUTION Damaged banjo bolt seating surfaces will leak when reassembled. 4 BRAKE FLUID. 3. Discard banjo washers. Remove and replace if damaged. such as gasoline or paint thinner. 1. See Figure 2-39. Check bleeder valve (metric). Clean all parts with denatured alcohol or D. 1. Pin Plug Mounting Screws (2) Bleeder Valve Wireform 2. Remove upper mounting screw (5) and brake line wireform (7) while supporting caliper above brake rotor. 6. See Figure 2-36. Separate carrier and caliper. 2. Do not contaminate with mineral oil or other solvents. See Figure 2-37. Figure 2-36. Slowly remove caliper by tilting away from wheel and then pulling away from rotor. Drain fluid only when disassembling caliper. Remove pad hanger pin (1) (metric). Discard seals.11 CLEANING AND INSPECTION 11WARNING 1WARNING Clean brake system components using denatured alcohol. Remove lower mounting screw (5).

O. Replace any parts that appear damaged or worn. Caliper Inner Seals Piston (2) Outer Seals Figure 2-39. c. (4. Failure to install brake pads as a set could result in death or serious injury. Apply a light coat of D. Caliper O-rings and Pistons 11WARNING 1WARNING Always replace brake pads in complete sets for correct brake operation. Pad Spring 2. Pad Hanger Pin (metric) Pad Spring Figure 2-37. Replace both pads as a set if the friction material of either pad is worn to 0. Replace if warped or badly scored.04 in. a. b. Do not hone caliper piston bore. a. pistons and caliper piston bores. ASSEMBLY 1. b. Tighten to 3-5 ft-lbs (4-7 Nm). Install pistons (3) in each piston bore. 4. 2. 2002 Buell P3: Chassis 2-25 . Inspect brake pads for damage or excessive wear. 3. d. Install two new seals in outer grooves of each piston bore.HOME 7702 7699 2 1 1. Measure rotor thickness. Removing Pistons 1 3 3 3. 2 4 1. Install two new seals in inner grooves of each piston bore. Check rotor surface. 2.18 in. (1. 4. See Figure 2-39.5 mm). Replace if minimum thickness is less than 0. 2. Inspect brake rotor. Carefully inspect all components.0 mm) or less. Install a new bleeder valve (metric) if necessary. Never replace just one brake pad. 7700 Figure 2-38. 4 BRAKE FLUID to seals. Install pistons and O-rings.T.

Actuate the brake lever with the reservoir cover removed. Install master cylinder cover (1) and cover gasket with two screws (2). 4 brake fluid. Turn ignition key switch to LOCK. 3. Remove both master cylinder cover screws (2). c. 2 1 2 1. See Figure 2-37. With the master cylinder in a level position. e. Route brake line through wireform.O. Install pin plug (4). Add D. Earlier silver banjo washers are not compatible with D. Spilling D. 11WARNING 1WARNING Always test motorcycle brakes at low speed after servicing or bleeding system. Turn ignition key switch to IGN.O.O.2 mm) from molded boss inside reservoir. Tighten to 11-15 ft-lbs (15-20 Nm). 4. Apply brake hand lever to test brake lamp operation. 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle. 2. 7. 4 BRAKE FLUID if necessary. Remove master cylinder cover (1) and gasket. verify that banjo washers. a.T. 4 fluid and will not seal properly over time. Install brake pads. CAUTION To avoid leakage.O. 8.) with D. NOTE Avoid making hard stops for the first 100 miles (160 km) to allow new brake pads to “wear in” properly with the brake rotor. or braking efficiency is poor. 10. 9. Insert outboard pad. b. a. 11WARNING 1WARNING Use only new black banjo washers (See Parts Catalog for Part No.HOME INSTALLATION 1. See Figure 2-36.O. Fit front brake caliper on rotor. See Figure 2-40.T. See Figure 2-36. Verify proper operation of the master cylinder relief port. Connect brake line (1) to caliper using two new banjo washers (3) and banjo bolt (2) (metric).52. Tighten to 1. Master Cylinder Cover Screws (2) Figure 2-40. Slide carrier on caliper.T. testing at high speeds could result in death or serious injury. verify that the brake fluid level is 0. Install pad hanger pin (1) (metric). Failure to have proper brake lamp operation could result in death or serious injury.T. Tighten to 16-20 ft-lbs (22-27 Nm).1 ft-lbs (2-3 Nm). (3. If brakes are not operating properly. Apply LOCTITE THREADLOCKER 272 (red) to both caliper mounting screws (5). hydraulic brake line and caliper bore are completely clean. Install wireform to upper screw and tighten both screws to 18-22 ft-lbs (24-30 Nm). A plugged or covered relief port can cause brake drag or lockup.0-1.125 in. 4 brake fluid on molded-in-color surfaces will result in cosmetic damage. b. A slight spurt of fluid will break the surface if all internal components are working properly. 11. d. Tighten to 9-13 in-lbs (1. Spilling brake fluid on switches may render them inoperative.5 Nm). Install pad spring (2) with opening at top as shown.T. CAUTION Cover molded-in-color surfaces and right handlebar switches and use care when removing brake reservoir cover and adding D. Insert inboard brake pad from rear of caliper. Depress front brake lever several times to set brake pads to proper operating position within caliper. Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury. See Figure 2-37. 6. Bleed brake system. Master Cylinder Cover 11WARNING 1WARNING Verify proper operation of the master cylinder relief port. 2. banjo bolt. Visibility is a major concern for motorcyclists. 7024 5. 4 brake fluid. which could result in loss of vehicle control and death or serious injury 2-26 2002 Buell P3: Chassis . Slide caliper over front brake rotor without brake pads installed.

See Figure 2-41. Refill master cylinder and bleed brakes. banjo bolt. CAUTION Damaged banjo bolt seating surfaces will leak when reassembled. Position brake line in wireform.O.T. 3. 1. Loosely install clamp (5) with screw (4) to attach front brake line to right side of lower triple clamp. Connect brake line to caliper using two new banjo washers (7) and banjo bolt (6) (metric). 3. 2 1 INSTALLATION 11WARNING 1WARNING Use only new black banjo washers (See Parts Catalog for Part No. hydraulic brake line and master cylinder bore are completely clean. 4 brake fluid. Remove brake line from wireform. 5. 4 fluid and will not seal properly over time. Earlier silver banjo washers are not compatible with D.HOME FRONT BRAKE LINE REMOVAL 1. Discard banjo washers. Turn ignition key switch to LOCK. Install bleeder valve if removed. Connect brake line to master cylinder using two new banjo washers (2) and banjo bolt (1) (metric). Remove master cylinder banjo bolt (1) (metric) and two banjo washers (2) to disconnect brake line from master cylinder. 5. Turn ignition key switch to IGN. Replace the brake line if any damage is noted. Drain and discard brake fluid. 6. 4 5 6 2. 4.10 FRONT BRAKE MASTER CYLINDER. 2. Top right sidemaster cylinder a0215x2x 3 4. Discard banjo washers.T. 4. 1. From the master cylinder.O. 5. Tighten banjo bolt (6) to 16-20 ft-lbs (22-27 Nm). Front Brake Line 2002 Buell P3: Chassis 2-27 . Remove caliper banjo bolt (6) (metric) and two banjo washers (7) to disconnect brake line from caliper.12 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle. 2. 7. cuts or other defects. 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. 2. where it turns inboard at the upper triple clamp. See Figure 2-41. Visibility is a major concern for motorcyclists. Loosely install bolt into master cylinder. Apply brake hand lever to test brake lamp operation. Remove screw (4) to detach brake line clamp (5) from right side of lower triple clamp. Carefully inspect the brake line for dents. Master Cylinder Banjo Bolt (metric) Banjo Washers (2) Brake Line Screw Wire Guide Caliper Banjo Bolt (metric) Banjo Washers (2) Figure 2-41. ensure that banjo washers. Prevent damage to seating surfaces by carefully removing brake line components. 6. Tighten clamp screw (4) on lower triple clamp to 3-5 ftlbs (4-7 Nm). Lower right sidebrake caliper 7 3. Failure to have proper brake lamp operation could result in death or serious injury.) with D. See Step 1 under 2. the brake line runs downward in front of the right handlebar. Tighten master cylinder banjo bolt (1) (metric) to 16-20 ft-lbs (22-27 Nm). 7.

Banjo Bolt (metric) Banjo Washers (2) Brake Line Master Cylinder Screw (2) (metric) Piston Assembly Push Rod 8. c. 14. Remove two screws (2) and spacers (3) to detach master cylinder from footrest support. 4. Discard all seals during the disassembly procedure. Install a complete rebuild kit upon assembly. Pump brake pedal to drain brake fluid. Remove banjo bolt (1) (metric) and two banjo washers (2) to detach brake line (3) from master cylinder (4). 4 5 14 6 7 8 9 10 11 12 1. See Figure 2-44. Snap Ring Rubber Boot Locknut Clevis Clevis Pin Remote Reservoir Spacer (2) Figure 2-43. b.13 Bleeder Valve (metric) Figure 2-42. Remove piston assembly (4) from master cylinder body. 3. Discard used fluids according to local laws. 9. 13. 2. 6. Drain brake fluid into a suitable container. Rear Caliper Bleeder Valve (Metric) a0123x2x 13 3. Reinstall cap. Spin locknut (10) away from top surface of clevis. 7723 2. 12. Rear Master Cylinder Assembly 2-28 2002 Buell P3: Chassis . Disconnect push rod from brake pedal clevis (11). See Figure 2-45. Install a length of plastic tubing over caliper bleeder valve. Remove cap from rear caliper bleeder valve. 3. 5. a. See Figure 2-42. b. Depress rod assembly (3) and remove internal snap ring (2). See Figure 2-43. CAUTION Damaged banjo bolt surfaces will leak when reassembled. d. 2. Prevent damage to seating surfaces by carefully removing brake line components. 3 1 2 DISASSEMBLY NOTE Do not disassemble master cylinder unless problems are experienced. 10. 1. 4. Discard snap ring. 5. 2.HOME REAR BRAKE MASTER CYLINDER REMOVAL 1. See Figure 2-43. Tighten bleeder valve (metric) to 3-5 ft-lbs (4-7 Nm). See Figure 2-46. 7. Place free end in a suitable container. Open bleeder valve (metric) about 1/2 turn. Discard banjo washers. Turn rod adjuster (7) to free rod from clevis (11). 11. Slide rubber boot on rod assembly (3) away from master cylinder body (1). a. Detach remote reservoir.

banjo bolt. Add brake fluid and bleed brake system. Place round side of rod assembly (3) over piston. verify that banjo washers. Thoroughly clean master cylinder and all brake system components. 2. ASSEMBLY 1. Replace if damaged. Earlier silver banjo washers are not compatible with D. Verify that vent holes on master cylinder are completely open and free of dirt or debris. 1 2 3 2 3 4 5 6 7 Inspect boot on front of master cylinder for cuts. A plugged or covered relief port can cause brake drag or lockup. With motorcycle in a level position. Tighten to 16-20 ft-lbs (22-27 Nm). Connect remote reservoir. 4 BRAKE FLUID if necessary. 11WARNING 1WARNING Use only new black banjo washers (See Parts Catalog for Part No. Turn rod adjuster (5) to obtain correct position.T. b. Tighten to 4-6 ft-lbs (5-8 Nm). Add D. 2. Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury. Examine walls of master cylinder reservoir for scratches and grooves. 6. attach remote reservoir to frame using screw. 5. NOTE Brake pedal height should be set so top surface of brake pedal is even with the top surface of the foot peg. a. into master cylinder. 3. 5. hydraulic brake line and bore of master cylinder are completely clean. Banjo Bolt (metric) Screw (2) (metric) Spacers Rubber Boot Rod Adjuster Locknut Clevis Figure 2-44. INSTALLATION 1.T. 4 brake fluid. b. check that brake fluid is between the upper and lower marks on reservoir. 2002 Buell P3: Chassis 2-29 . 1.T. 11WARNING 1WARNING Verify proper operation of the master cylinder relief port. Do not use mineral-base cleaning solvents. 2. Set brake pedal height. See Figure 2-44. 2. Tuck rubber boot on rod assembly (3) into master cylinder body (1). Apply LOCTITE THREADLOCKER 243 (blue) to both screws. Install push rod by screwing push rod into clevis. tears or general deterioration.) with D.O.HOME CLEANING AND INSPECTION 7704 11WARNING 1WARNING Clean brake system components using denatured alcohol. 4 fluid and will not seal properly over time. This could result in improper brake operation which could result in death or serious injury. See Figure 2-45. a. Depress piston into master cylinder body (1) and secure with a new snap ring (2). If removed. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. 7. 4. See Bleeding Brakes. Replace if necessary. Master Cylinder Mounting 4. See Figure 2-44.O. Attach master cylinder (3) to frame with spacers between master cylinder and footrest support. which could result in loss of vehicle control and death or serious injury 6. Loosen locknut (6).7 Nm). See Figure 2-43.O. c. See Figure 2-46. Insert piston assembly (4). 3. Attach reservoir hose to master cylinder with clamp (if removed). spring first. Tighten locknut (6). 3. Be sure gasket and cap on reservoir fit securely. a. CAUTION To avoid leakage after assembly.4-1. 1. Connect brake line (3) to master cylinder (4) with two new banjo washers (2) and banjo bolt (1) (metric). such as gasoline or paint thinner. Tighten to 12-15 in-lbs (1. 7. Stand master cylinder on wooden block or towel to protect seating surfaces. b.

4. Visibility is a major concern for motorcyclists. Turn ignition key switch to LOCK. Turn ignition key switch to IGN. If brakes are not operating properly. 8. Master Cylinder Body Snap Ring Rod Assembly Piston Assembly Figure 2-46. 3. Apply rear brake pedal to test brake lamp operation.HOME 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle. Figure 2-45. or braking efficiency is poor. 2. Master Cylinder Internals 2-30 2002 Buell P3: Chassis . Failure to have proper brake lamp could result in death or serious injury. testing at high speeds could result in death or serious injury. Remote Reservoir 6506 1 2 4 3 1. 7703 11WARNING 1WARNING Always test motorcycle brakes at low speed after servicing or bleeding system.

Rear Brake Caliper (Typical) 2002 Buell P3: Chassis 2-31 . Drain and discard brake fluid. Remove clip (1) from caliper body. 1. 4. Remove small screw (6) (metric) and large screw (7) (metric) to detach caliper from mount. Remove banjo bolt (2) (metric) and two banjo washers (3) to disconnect brake line (1) from caliper. Prevent damage to seating surfaces by carefully removing brake line components.HOME REAR BRAKE CALIPER REMOVAL 6486 2. See Figure 2-49. 2. Discard O-rings. DISASSEMBLY 2 1. See Figure 2-48. 3. Remove pin plug and pad hanger (5) (metric) to free brake pads. Brake Line Banjo Bolt (metric) Banjo Washers (2) Bleeder Valve (metric) Pin Plug and Pad Hanger (metric) Small Screw (metric) Figure 2-47.14 NOTE Steps 1 and 2 are not required for detaching caliper from rotor. 2. 3. B-42887) with adaptor (2). See Figure 2-48. See Figure 2-47. 3. 5. 2. Caliper Mount Clip 3. 4. Clip Rear Caliper Mount Figure 2-48. Remove two O-rings from groove in caliper bore. 6496 2 1 1. 2. Remove piston (3) using BRAKE CALIPER PISTON REMOVER (1) (Part No. 6. 1 3 4. Remove clip (1) from rear caliper mount (2) if necessary. See Figure 2-47. CAUTION Damaged banjo bolt seating surfaces will leak when reassembled. 2. 7723 4 2 3 5 1. Brake Caliper Piston Remover Adaptor Piston Figure 2-49. Drain fluid only when disassembling caliper. Discard banjo washers. Removing Rear Brake Caliper Piston 1 6 7 1.

Verify proper fluid level in reservoir.) with D. Install a new bleeder valve (metric) if necessary. lint free cloth. piston and caliper piston bore. 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. Place clip (1) inside caliper body as shown. See Figure 2-50. a.O. Place two new O-rings inside grooves of piston bore.5 mm). Install caliper mount clip (1) if removed. 4 BRAKE FLUID to Orings. banjo bolt. Tighten to 1822 ft-lbs (24-30 Nm) Install small caliper screw (6) (metric). b.5-2. Inspect brake rotor. 4.O. Turn ignition key switch to IGN. 4. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. Install piston inside caliper body. 2. This could result in improper brake operation which could result in death or serious injury. 6. 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle. Apply brake pedal to test brake lamp operation. Clean all parts with denatured alcohol or D. 2. Visibility is a major concern for motorcyclists. b.O.T. 3. 1. piston must be pressed all the way into the bore whenever new brake pads are used. Install brake pads (3) using pad hanger and pin plug (2).18 in. 3. Install caliper assembly on caliper mount. 11WARNING 1WARNING Always replace brake pads in complete sets for correct brake operation. ASSEMBLY 1. Failure to install brake pads as a set could result in death or serious injury. Install pistons and O-rings. Failure to have proper brake lamp operation could result in death or serious injury. hydraulic brake line and caliper bore are completely clean. Apply a light coat of D. INSTALLATION 1. 4 brake fluid. Install pad hanger pin (metric). To prevent death or serious injury. Do not use a wire or similar instrument to clean drilled passages. Do not contaminate with mineral oil or other solvents. 11WARNING 1WARNING Always test motorcycle brakes at low speed after servicing or bleeding system. c. Install large caliper screw (7) (metric).O. Depress rear brake pedal several times to set brake pads to proper operating position within caliper.0 mm) or less. b. See Figure 2-50. Replace both pads as a set if the friction material of either pad is worn to 0. 4. 5. Carefully inspect all components. 3. Buell strongly recommends that all brake repairs be performed by a Buell dealer or other qualified technician. NOTE To ensure proper brake pad-to-brake rotor clearance when the caliper is installed. c. such as gasoline or paint thinner. verify that banjo washers. Tighten to 11-15 ftlbs (15-20 Nm). Do not hone caliper piston bore. 4 fluid and will not seal properly over time. 4 BRAKE FLUID. Replace if warped or badly scored. (4. Connect brake line (1) to caliper using two new banjo washers (3) and banjo bolt (2) (metric). Blow out drilled passages and bore with a clean air supply. Wipe dry with a clean. Inspect brake pads for damage or excessive wear. Apply LOCTITE THREADLOCKER 271 (red) to both caliper mounting screws (6.T. Brake pad surfaces must face rear brake rotor.T. See Figure 2-47. Tighten to 1518 ft-lbs (20-24 Nm). Check rotor surface. Replace any parts that appear damaged or worn. Tighten to 16-20 ft-lbs (22-27 Nm). a.04 in. a. Earlier silver banjo washers are not compatible with D.T. Tighten to 1.HOME CLEANING AND INSPECTION 11WARNING 1WARNING Clean brake system components using denatured alcohol. Bleed brake system. Replace if minimum thickness is less than 0. (1. See Figure 2-48. Measure rotor thickness. Turn ignition key switch to LOCK. 2002 Buell P3: Chassis 2-32 . NOTE Avoid making hard stops for the first 100 miles (160 km) to allow new brake pads to “wear in” properly with the brake rot. Install pin plug. a. 11WARNING 1WARNING Use only new black banjo washers (See Parts Catalog for Part No. Never replace just one brake pad. Tighten to 3-5 ft-lbs (4-7 Nm). 2. 7) (metric).1 ft-lbs (2-3 Nm). Do not use mineral-base cleaning solvents. b.

Ineffective brake – lever/pedal travel normal. Distorted or glazed rotor. Rear brake pedal linkage out of adjustment. Loose mounting bolts. Air in system. Master cylinder low on fluid. Replace rotor. Cup in master cylinder not uncovering relief port. 2. Fill master cylinder with approved brake fluid. Low fluid level. Replace rotor. 3. Piston cup not functioning. glazed or contaminated brake pads. Warped rotor. Fill master cylinder with approved brake fluid. Replace brake pads. Bleed brake(s). Fill master cylinder with approved brake fluid. Replace pads. Brake Troubleshooting CONDITION Excessive lever/pedal travel or spongy feel. and bleed system. Rebuild cylinder. Inspect master cylinder. Brake pads drag on rotor – will not retract. Worn pads. Clip Pin Plug and Pad Hanger (metric) Brake Pads (2) Figure 2-50. CHECK FOR Bleed brake(s). Moisture in system. Tighten bolts. REMEDY Brake fade 2002 Buell P3: Chassis 2-33 . Chattering sound when brake is applied. Adjust linkage. Distorted.HOME 6487 1 2 1. Brake Pads 3 Table 2-4. Ineffective brake – lever/pedal travels to limit.

2. Bolt Damper Bushing Damper Nut Stopper Ring Spring Seat Spring Spring Seat Stopper Figure 2-51. 4 2 1 5 6 5. Raise motorcycle off lift until rear suspension is unloaded. 1. 7 INSTALLATION 1. 7. B-41174) See 2.28 SEAT. Rear Shock Absorber Assembly 2-34 2002 Buell P3: Chassis . 7. 8 11WARNING 1WARNING After installing seat. a0015xSx 2. it could shift during vehicle operation causing loss of control of vehicle and death or serious injury. 4. pull upward on front of seat to be sure it is locked in position. Attach lifting straps to a floor hoist placed behind the motorcycle. 3. Tighten top bolt to 35-40 ft-lbs (47-54 Nm). See Figure 2-51. Tighten bottom bolt to 35-40 ft-lbs (47-54 Nm). 2. See Figure 2-51. NOTE Rear shock absorber contains no user serviceable parts. 2. Remove lifting straps and install seat. Loosely install top bolt and nut. remove the bolt (1) and nut (4) from the bottom mount. Attach lifting straps to motorcycle. 4. Loosely install bottom bolt and nut. Insert lifting straps under frame tubes. Place new damper bushings (2) into mounting holes of shock absorber (if not installed). Remove seat.15 4 3 2 1 REMOVAL 1. NOTE Torque bolts and nuts from the bolt side only. 6. While supporting the shock absorber. Remove shock absorber assembly.28 SEAT. The rear suspension preload and compression and rebound damping are controlled by a non-adjustable shock absorber. See Figure 2-51. Lift rear wheel off ground using REAR WHEEL SUPPORT STAND (Part No. 3. 6. 5. If seat is loose. See 2. 3.HOME REAR SHOCK ABSORBER GENERAL See Figure 2-51. 5. 8. 6. 4. Remove bolt (1) and nut (4) on top mount.

Screw (short. Cut cable ties along frame. Attach housings with two screws. 6853 2. See 4. 9. 5. Blow dry with compressed air.2 FUEL TANK COVER/FUEL TANK. 4. Remove fuel tank assembly. Remove throttle cable clamp.2 FUEL TANK COVER/FUEL TANK. Throttle Control Cables 3. 3 4 1 5 2 Throttle Control Cable Idle Control Cable Cable Adjuster Lock Cable Adjuster Rubber Boot Figure 2-52.16 2. Route cables as noted in step 9. Separate housings from handlebar. kinked or bent. 2002 Buell P3: Chassis 2-35 . 6. See 1. bottom) Ferrules Cable Wheel Rear Housing Locating Pin Figure 2-53. Slide rubber boot off the cable adjusters. Remove cables from notches in housings. Position ferrules on cable wheel. 4. Loosen cable adjuster lock on each adjuster. 7098 CLEANING AND INSPECTION Clean all parts in a non-flammable cleaning solvent. Remove two screws on front housing. 1 6 8 7 4 9 5 ASSEMBLY/INSTALLATION 1. 9. Carefully note the routing of the cables through/around the forks. 2. 10. installing longer screw on bottom. 3. Install fuel tank. Unhook ferrules from cable wheel. 6. 6. 2. 3. 4. Insert idle control into front switch housing. 3. 8. Replace cables if frayed. Slide switch housing over throttle. 5. See Figure 2-52. 9. Pull cables toward the rear.HOME THROTTLE CONTROL REMOVAL/DISASSEMBLY 1. 2 4. 7. Remove cables from throttle. 8. 2. Insert throttle cable into front switch housing. Use LOCTITE THREADLOCKER 222 (purple) on screw. 3 10 1. 8. Cable Connections Attach rear switch housing and position housings on right handlebar by engaging locating pin on front housing with hole in handlebar. Adjust cables. 5. Connect cables at carburetor. 7. 10. 5. Attach throttle cable clamp.18 THROTTLE CABLES. 7. Tighten to 12-17 inlbs (1-2 Nm). 1. top) Cable Adjusters (2) Idle Control Cable Throttle Control Cable with Molded End Front Housing Screw (long. See 4. along the frame backbone and front/rear of handlebars.

HOME NOTES 2-36 2002 Buell P3: Chassis .

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