2003 Buell P3: Maintenance 1-17
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CLUTCH 1.9
GENERAL
Check clutch for proper adjustment:
● At the 1000 mile (1600 km) initial service and at every
5000 mile (8000 km) service interval thereafter.
Oil and adjust the clutch control cable:
● Every 5000 miles (8000 km) with LUBIT-8 TUFOIL
CHAIN AND CABLE LUBE (Part No. 94968-85TV).
ADJUSTMENT
Clutch control cable adjustment is required at this interval to
compensate for normal clutch lining wear. If the clutch slips
under load, or drags when released, adjust the clutch control
cable.
1. Raise rear wheel off floor using REAR WHEEL SUP-
PORT STAND (Part No. B-41174).
2. Remove left footpeg support bracket. See 2.21 FOOT-
PEGS AND FOOTPEG SUPPORT BRACKETS.
3. See Figure 1-12. Slide rubber boot (1) upward to expose
adjuster mechanism. Loosen jam nut (3) from adjuster
(4). Turn adjuster to shorten cable housing until there is a
large amount of freeplay at clutch hand lever.
4. See Figure 1-13. Remove three TORX screws with
washers (1) from clutch inspection cover (2). Remove
clutch inspection cover from primary cover.
NOTE
Quad ring removed from primary cover for illustrative pur-
poses only in Figure 1-13.
5. Remove spring (4) and lockplate (5). Turn adjusting
screw (6) counterclockwise until it lightly bottoms.
6. Turn adjusting screw (6) clockwise 1/4 turn. Install lock-
plate (5) and spring (4) on adjusting screw flats. If hex on
lockplate does not align with recess in outer ramp, rotate
adjusting screw clockwise until it aligns.
7. Squeeze clutch hand lever to maximum limit three times.
This sets the ball and ramp mechanism. Pull outer cable
conduit and at the same time adjust cable adjuster to
provide 0.0625-0.125 in. (1.6-3.2 mm) freeplay at clutch
hand lever.
Figure 1-12. Clutch Cable Adjuster Mechanism
a0159x6x
1. Rubber boot
2. Cable end
3. Jam nut
4. Adjuster
4
3
2
1
Figure 1-13. Clutch Release Mechanism
1. TORX screw
2. Clutch inspection cover
3. Quad ring
4. Spring
5. Lockplate
6. Adjusting screw
a0155x6x
2
1
3
4
5
6
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