3-10 2002 Buell S3T: Engine
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INSTALLING THE ENGINE 3.4
ENGINE CRANKCASE
INSTALLATION
1. See Figure 3-2. Place engine crankcase on supports so
frame may be installed over the top of the engine.
2. See Figure 3-3. If removed, attach swingarm mount
block to engine. Install upper bolts (3), washers and lock-
nuts finger tight. Install lower bolts (4), washers and lock-
nuts finger tight. Tighten upper bolts to 41-45 ft-lbs
(56-61 Nm) and lower bolts to 68-75 ft-lbs (92-102 Nm).
3. If removed, install swingarm. Adjust swingarm bearing
preload. See 2.19 SWINGARM.
4. If removed, install transmission mainshaft sprocket. See
6.13 TRANSMISSION INSTALLATION AND SHIFTER
PAWL ADJUSTMENT.
5. Remove oil filter (if installed). Walk frame over powertrain.
6. See Figure 3-4. Attach front isolator (8). Install front iso-
lator mount with bolt (6), washers (7), D-washer (9) and
locknut (10). Flat on D-washer faces steering neck (for-
ward). Tighten bolt finger tight.
7. See 2.20 REAR ISOLATORS for installation. Install rear
isolators but do not tighten isolator bolts at this time.
CAUTION
Do not adjust tie bar assemblies. Tie bar tension is set at
the factory. Any attempt at adjusting tension will cause
damage to tie bars. Damaged tie bars must be replaced.
8. See Figure 3-3. Rear tie bar must be horizontal and
below frame tab. Insert bolt upwards through washer, tie
bar and frame. Fasten with nut. Tighten bolt to 30-33 ft-
lbs (41-45 Nm).
9. See Figure 3-4. Place clutch cable clamp (3) on front tie
bar bolt (2). Clamp should hold cable on primary cover
side of motor. Insert bolt from front through frame and
install washer (4). Continue through tie bar (1) and
frame. Install locknut (5) and tighten to 30-33 ft-lbs
(41-45 Nm).
10. Attach front upper tie bar (11). Insert bolt through tie bar
front isolator, and frame. Secure with nut and washer.
Tighten to 30-33 ft-lbs (41-45 Nm).
11. See Figure 3-3. Tighten the two rear isolator TORX bolts
to 63-70 ft-lbs (85-95 Nm)
12. See Figure 3-4. Tighten front isolator bolt (6) to
100-110 ft-lbs (136-149 Nm).
13. Connect feed, return and vent lines to oil tank. See 3.8
OIL HOSE ROUTING. Use
new
hose clamps.
14. Attach battery ground strap to swingarm mount block.
15. Attach clutch cable to handlebar lever.
16. Remove strap from between engine cylinders. Using a
floor hoist, lift motorcycle by the frame and remove the
wooden cradle from underneath the crankcase.
17. Install rear shock. See 2.21 REAR SHOCK ABSORBER.
Remove floor hoist straps.
18. Install rear wheel and attach drive belt. See 2.6 REAR
WHEEL.
19. Install rear brake caliper. See 2.14 REAR BRAKE CALI-
PER.
20. Attach disconnected wires. See Section 7.
a. Connect solenoid wire, circuit breaker charging wire
and battery positive cable to starter.
b. Connect voltage regulator connector to alternator
stator wiring.
c. Attach cam position sensor to wire harness.
d. Connect neutral switch wire to crankcase.
e. Attach oil pressure indicator switch wire.
21. Install rear fender and lower belt guard. See 2.32 REAR
FENDER.
22. Install sprocket cover. See 2.29 SPROCKET COVER.
23. Install footrests. See 2.28 FOOTRESTS.
24. Continue with the steps listed under ENGINE INSTAL-
LATION AFTER CYLINDER HEAD REPAIR.
ENGINE INSTALLATION AFTER
CYLINDER HEAD REPAIR
1. Install
new
oil filter, engine oil and primary chaincase
fluid as necessary. See Section 1.
2. Install intake manifold, throttle body and ignition key
switch bracket. See 4.40 THROTTLE BODY AND
INTAKE MANIFOLD.
a. Plug ignition key switch connector into main wiring
harness.
b. Connect sensor connectors to sensors.
3. Install exhaust system. See 2.27 EXHAUST SYSTEM.
4. Install air cleaner assembly. See 4.41 AIR CLEANER.
5. If removed, install horn (7.6 HORN) and ignition coil (7.4
IGNITION COIL).
6. Install spark plugs and connect cables. See 1.17 SPARK
PLUGS.
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