4-26 2002 Buell P3: Fuel System
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INSTALLATION
1. Obtain new throttle position sensor. If old sensor is used,
inspect O-ring for cuts, tears or signs of deterioration.
Replace O-ring if necessary. See Figure 4-24.
2. Align holes in throttle position sensor with those in carbu-
retor housing. Using special TORX bit (Snap-on®
TTXR20E), loosel
y install two tamper-resistant T20
TORX screws.
NOTE
The tamper-resistant screws are not to be tightened until the
throttle position sensor has been properly adjusted. See the
instructions under step 6 for details.
3. Locate 6-place Deutsch connector and install pin termi-
nals in chambers 3 through 5. Mate pin and socket
halves of connector.
NOTE
For instructions on properly installing wire terminals, see
Appendix B.
4. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (7-11 Nm).
5. Standing on the right side of the vehicle, start air box into
opening. When partially installed, push PCV outlet hose
onto middle fitting of 3-way connector, and loosely install
carburetor onto manifold-carburetor coupler.
6. Adjust throttle position sensor as follows:
a. Back off idle adjustment screw so throttle plate is
fully closed.
b. Completely open and close the throttle by rotating
the throttle control through its full range of motion.
c. Using special TORX bit (Snap-on® TTXR20E),
loosen the two tamper-resistant T20 TORX screws
just enough to allow sensor to rotate.
d. Disconnect pin 3 in connector [88B] (main wire har-
ness).
e. Install Breakout Box Adaptors (HD-42962) and
Breakout Box (HD-42682) using black connectors
between connector halves [88A] and [88B].
f. Turn ignition switch to ON. Using a multimeter, mea-
sure voltage between pin 3 (V/W) and pin 5 (BK).
g. Adjust (rotate) throttle position sensor (TPS) until
voltage reading is 0.5V +/- 0.05V.
h. Completely open and close the throttle by rotating
the throttle control through its full range of motion.
Wide Open Throttle (WOT) should not exceed 3.7V
and reading should increase consistently as throttle
is opened. If the voltage reading is erratic or the volt-
age reading at WOT exceeds 3.7V see Figure 7-10.
for diagnostic testing.
NOTE
After WOT, the TPS reading may not return back to exactly
0.5V +/- 0.05V. To re-check exact TPS voltage reading, turn
cycle key off and on.
i. Tighten TP Sensor mounting screws to 13-23 in-lbs
(2-3 Nm).
7. Moving to opposite side of vehicle, apply a small dab of
Loctite Low Strength Threadlocker 222 (Purple) to
threads of two flange bolts. Slide bolts through top two
holes of triangular bracket and install into left side of air
box. Alternately tighten screws to 3-5 ft-lbs (4-7 Nm).
8. Returning to the right side of the vehicle, fix position of
carburetor on manifold-carburetor coupler. Turn slotted
screw to tighten band clamp on outboard side of coupler.
9. Apply one drop
of Loctite High Strength Threadlocker
262 (red) to threads of hex screw. Install screw at bottom
of air box (6 o’clock position) to secure air box bracket to
crankcase hole. Tighten screw to 10-12 ft-lbs (14-16
Nm).
10. Taking note of index pin on inboard side of cover and
small depression at tip of cone, position cover onto air
box so that pin engages depression.
11. Lock five latches around perimeter of air box cover.
12. Install Phillips screw at bottom of air box cover (7 o’clock
position) to secure cover to air box. Tighten screw to 4-6
in-lbs (0.5-0.7 Nm).
13. Position seat on frame backbone, so that tongue at bot-
tom engages slot in frame weldment. Push down on rear
of seat until spring-loaded latch fully engages groove of
seat pin.
11WARNING1WARNING
Pull up on seat to verify that it is properly secured, front
and rear. A loose seat may shift during vehicle operation
and startle the rider, possibly causing loss of vehicle
control that could result in death or serious injury.
14. Adjust engine idle speed, as follows:
NOTE
Be sure the engine is warmed up to normal operating temper-
ature BEFORE adjusting engine idle speed.
a. With the engine at normal operating temperature
(auto-enrichener valve closed), adjust the throttle
stop screw so the engine idles at 1200 rpm.
NOTE
To measure engine rpm, use a hand held inductive tachom-
eter (Snap-on® ONO-SE-1100) to pick up the signal off the
spark plug cable.
Throttle Position Sensor Connector
Chamber
Number
Wire Color Function
3Light Blue Output
4Yellow Input
5Black Ground
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