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Buell 2002 P3 User Manual

Buell 2002 P3
400 pages
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2002 BUELL P3
SERVICE MANUAL
Part Number 99491-02Y
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive/Transmission
Section 7: Electrical
Appendix

Table of Contents

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Buell 2002 P3 Specifications

General IconGeneral
BrandBuell
Model2002 P3
CategoryMotorcycle
LanguageEnglish

Summary

Section 1: Maintenance

1.1 GENERAL

Covers general service information, safety precautions, and shop practices for motorcycle maintenance.

1.2 FLUID REQUIREMENTS

Details the types and quantities of fluids required for the motorcycle's various systems.

1.4 BATTERY

Instructions for disconnecting, removing, installing, and connecting the motorcycle battery.

1.5 ENGINE LUBRICATION SYSTEM

Information on checking and changing engine oil and filter, including recommended oil grades.

1.6 BRAKE SYSTEM MAINTENANCE

Procedures for checking brake fluid levels, bleeding brakes, and maintaining the brake system.

1.7 BRAKES PADS AND ROTORS

Instructions for inspecting and replacing brake pads and rotors, including wear limits.

1.8 TIRES AND WHEELS

Information on tire inflation, wheel bearings, and tire specifications.

1.9 CLUTCH

Procedures for checking and adjusting the clutch control cable and release mechanism.

1.10 TRANSMISSION/PRIMARY FLUID

Guidelines for inspecting and changing transmission and primary chain case lubricant.

1.11 DRIVE BELT AND REAR SPROCKET

Instructions for inspecting, cleaning, and replacing the drive belt and rear sprocket.

1.12 PRIMARY CHAIN

Procedures for adjusting the primary chain tension.

1.13 REAR SHOCK ABSORBER

Information on inspecting the rear shock absorber for proper operation and oil leaks.

1.14 FRONT FORK OIL

Instructions for draining and refilling the front forks with fresh fork oil.

1.15 STEERING HEAD BEARINGS

Procedures for checking, lubricating, and adjusting the steering head bearings.

1.16 SPARK PLUG

Guidelines for changing, inspecting, and testing spark plugs, including gap specifications.

1.17 AIR CLEANER

Procedures for removing, cleaning, inspecting, and installing the air cleaner element and assembly.

1.18 THROTTLE CABLES

Instructions for lubricating and adjusting throttle control cables for proper operation.

1.19 IGNITION TIMING AND IDLE SPEED ADJUSTMENT

Procedures for checking and adjusting ignition timing and engine idle speed.

1.20 FUEL SUPPLY VALVE AND FILTER STRAINER

Instructions for inspecting the fuel supply valve, lines, and cleaning the filter strainer.

1.21 STARTER INTERLOCK AND ELECTRICAL SWITCHES

Information on lubricating the sidestand and inspecting electrical equipment and switches.

1.22 CRITICAL FASTENER TORQUE VALUES

A comprehensive list of torque specifications for critical fasteners on the motorcycle.

1.23 STORAGE

Guidelines for preparing the motorcycle for extended storage to prevent corrosion and maintain battery health.

1.24 TROUBLESHOOTING

A diagnostic guide to help identify and resolve common operating problems.

CHASSIS

2.1 SPECIFICATIONS

Provides detailed specifications for the motorcycle's chassis components, including dimensions and weights.

2.2 TIRE SPECIFICATIONS

Lists tire sizes, pressures, and fitment information for tubeless cast wheels.

2.4 WHEELS

General information on wheel care, tire inspection, and troubleshooting handling irregularities.

2.5 FRONT WHEEL

Detailed procedures for removing, disassembling, cleaning, and inspecting the front wheel.

ENGINE

3.1 SPECIFICATIONS

Provides detailed specifications for engine components, including bore, stroke, and compression.

3.3 STRIPPING MOTORCYCLE FOR ENGINE REPAIR/ REMOVAL

Detailed instructions on how to prepare the motorcycle for engine disassembly and removal.

3.4 ENGINE INSTALLATION

Step-by-step guide for reinstalling the engine, including torque specifications and component connections.

FUEL SYSTEM

4.1 SPECIFICATIONS

Provides specifications for fuel tank capacity, carburetor jet sizes, and adjustments.

ELECTRIC STARTER

5.1 SPECIFICATIONS

Provides specifications for the starter motor, including free speed, current, and torque values.

5.3 STARTER DIAGNOSTICS

Outlines procedures for diagnosing starting system problems using voltage and continuity tests.

5.5 DIAGNOSTICS/TROUBLESHOOTING

Provides troubleshooting charts for common starting system problems.

DRIVE/TRANSMISSION

6.1 SPECIFICATIONS

Provides specifications for primary drive, final drive, transmission lubricant, and gear ratios.

6.14 TRANSMISSION INSTALLATION

Step-by-step guide for installing the transmission assembly into the crankcase halves.

ELECTRICAL

7.1 SPECIFICATIONS

Provides electrical specifications for the battery, alternator, regulator, ignition system, and electrical system components.

7.3 DIAGNOSTIC CHARTS

Diagnostic flow charts for troubleshooting ignition system problems like no spark.

7.13 CHARGING SYSTEM

Troubleshooting guide for charging system failures, including battery, wiring, stator, and regulator checks.

7.27 SPEEDOMETER PERFORMANCE CHECK

Procedures for testing speedometer operation, needle sweep, and sensor signal accuracy.

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