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Buell Blast Owners Manual Download - [Unlimited PDF]
And by having access to our ebooks online or by storing it on your computer, you have convenient answers with Buell Blast Owners Manual Download. To get started finding Buell Blast Owners Manual Download, you are right to find our website which has a comprehensive collection of manuals listed. Our library is the biggest of these that have literally hundreds of thousands of different products represented. I get my most wanted eBook Many thanks If there is a survey it only takes 5 minutes, try any survey which works for you. This manual has everything you ever wanted to know about servicing your blast, from oil changes, to electrical work, or just tinkering on the Buell Blast engine. So, without a lot of fanfare, here are links to each chapter in the Service Manual for you to reference or download. No payment required, no waiting for a book or CD to be delivered, all is right here for your reference and use. Hopefully this will help you as much as it helped me. Edit: Getting lots of feedback on how helpful this has been to everyone, glad I could assist. Please feel free to pass the link along to other Blast riders. Even though I no longer own my Blast, rest assured I will keep this link active for everyone that needs to download the Buell Blast Maintenance Manual. Filed Under: Motorcycles Tagged With: buell blast, Motorcycle Comments Yolys Sanz says December 2, 2012 at 1:22 pm muuuchas gracias!! Reply Steve says May 11, 2013 at 9:15 am Thanks, dude. Reply twofry says May 19, 2013 at 9:54 pm This, is awesome, thank you so much!! Reply Salvador Ramirez says July 19, 2019 at 7:40 am Muchas gracias por la ayuda amigo acabo de adquirirla aun no me le subo pero estoy muy emocionado y quiero tener todo sobre ella a la mano por si fallara saber que Aser Reply ted thorne says May 28, 2013 at 2:13 pm yes, thank you.Can’t believe I can dowload it all and for zero cost.
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Reply Jack says July 20, 2013 at 12:06 pm Thank you so very much, you have no idea how much this helped me with wiring my buell Reply Ang3lito says November 19, 2013 at 6:37 pm You’re big man, very thanks from a Spanish boy in Mexico. Reply Juan Leon says December 2, 2013 at 8:39 am Eres grande amigo. Gracias por compartirlo. Saludos de Guatemala. Reply KenMcDaniel says September 30, 2014 at 7:03 pm Very well done. Most info i have found. Thanks for posting. You are ok i dont care what other people may think of you. Thanks again. Reply Daniel McDevitt says October 5, 2014 at 2:40 pm Anyone know size of exhaust nuts and bolts Reply robert schuchman says December 26, 2014 at 9:49 pm I to would like to thank you very helpful Reply Vincent S says March 18, 2015 at 7:47 pm What A Lifesaver Thank You Reply B37 says November 8, 2015 at 11:44 pm Kudos. You’ve helped a lot of us. Reply bruce says July 12, 2018 at 12:26 am how may I get a manual for 2001 Buell blast Reply Craig says July 18, 2018 at 6:57 am They are basically all the same, regardless of year. If you are looking for a paper manual, follow the link in this posts as you can purchase on Amazon. Reply cody denver says January 11, 2016 at 1:01 pm hey Craig. They seemed to have changed a lot between the two years. I’m fairly certain not much changed on these bikes across the model years. Reply Frida Ross says May 10, 2016 at 1:32 pm Thank you the manual is great, but I’m trying to find out what parts are interchangeable. I have a 2001 and ineedthrrt handcontrol switch, key ignition switch, stater, and voltage regulator. What years of blast parts are usuable for my bike bike Reply Kendall says May 13, 2016 at 12:56 am You’ll want to consult with a Harley dealer. They will have the Buell books and can tell you all years which will use the same part numbers as yours.Reply Kendall says May 13, 2016 at 12:54 am THANK YOU!! Funny, as I’m also an IT guy who took up biking and my first one is an 02 Blast.
I will be fixing it up and this manual has already proven indispensable. Reply Craig says May 13, 2016 at 11:30 am Awesome. Glad to hear it’s helpful. I still regret selling mine. Reply HECTOR MIRANDA says May 29, 2016 at 12:16 am GOOD AND EXELENT CONTRIBUTION THANK YOU VERY MUCH.My neighbor is giving me his 2000 Buell Blast and it has been sitting in a dry garage for over 10 years. It looks great, but I am going to be examining everything on it to insure function and reliability. I know that I will be visiting this site to glean service information from the manual. Again, I am very grateful for your kindness in making this possible. Reply Craig says July 29, 2016 at 6:37 pm Good for you. Nothing better than a free bike. Reply mark says August 13, 2016 at 11:50 am could not get it to down load Reply Craig says August 15, 2016 at 9:44 pm Not sure, I double checked and all seems to be fine. Maybe try to clear your browser cache and try again. Reply Steve says October 8, 2016 at 3:34 am Many thanks its fantastic your great Reply klndle says May 6, 2017 at 3:29 am This Service Manual has easy-to-read text sections with top quality diagrams and instructions. Reply Russ says June 22, 2017 at 9:59 am Thank you, thank you, thank you for posting this. I’ve been looking all over trying to find this information, and even hard copies are becoming more rare (and expensive). I rode extensively up until 2001 when my last bike was stolen. Now that the kids are older, I find myself frequently without a car. I just picked up a 2008 Buell Blast and it’s become by daily commuter. Ride on! -r Reply Craig says June 22, 2017 at 2:36 pm I’m glad you found this helpful Russ.
Reply Josh says October 7, 2017 at 12:39 pm Anyone know why my 2001 Buell Blast only starts with starting fluid when there is a full tank of gas the hose leading to the carb and the carb have been cleaned twice Reply Thomas Wyszynski says March 17, 2018 at 8:07 pm Anyone know where i can find a manual for an 09 buell blast. Does anyone have this chapter so I can have a complete copy. Reply Craig says April 12, 2018 at 6:57 am Are you getting an error message or does the page simply not display. It just worked fine for me. The rest give a “The page isn’t redirecting properly” error. Reply Craig says July 31, 2018 at 9:05 am Interesting. Just tried it from my work computer and received a similar error, although I am able to get to some of the links you can’t. Appears to be an issue with the CDN I’m using. I’ll fix as soon as I can, but it will probably be a day or two until I’m able to get to this. Reply Amy says June 3, 2019 at 11:21 am Hi there. I’m still getting a “cdn.craigerson.com redirected you too many times” for the Electrical page. Is this PDF still available. You can also email me if that’s easier. Craig says June 20, 2019 at 4:22 pm Hey Amy. Sorry I’m just replying to this. I just tried to access that page and it worked fine for me. Possibly try clearing your cookies or use an incognito window. Let me know if that doesn’t work, and I’ll take a further look. Amy Bashara says June 21, 2019 at 5:38 pm You’re right. It worked this time. Thank you!! Theo says July 31, 2018 at 7:13 pm Any chance you could set up something like a Dropbox share for the files. Reply Jsharky says May 16, 2019 at 4:35 pm Thanks Craig, your post of the manual came as a very welcome relief. I’ve downloaded all files and and am very happy. This will help greatly. Thank you! Reply game says June 1, 2020 at 12:43 pm I enjoy, cause I discovered exactly what I used to be looking for. You have ended my 4 day lengthy hunt. God Bless you man. Have a nice day.
Bye Reply brdavis9 says June 19, 2020 at 8:03 pm Still useful. Thanks! Reply David Hepburn says July 7, 2020 at 3:47 pm Thank you so much. I just got a 2001 Blast. You are a life saver. Reply Leave a Reply Cancel reply Your email address will not be published. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with 2001 Buell Blast Owners Manual. To get started finding 2001 Buell Blast Owners Manual, you are right to find our website which has a comprehensive collection of manuals listed. B-43983 Main Drive Gear Cross Plate. Part No. B-41174-2 Replacement Pad. Used with Part No. HD-33223-1 Cylinder Compression Gauge Part No. B-59000A Pro Level Oil Gauge Part No. HD-33413-A Carburetor Idle Adjustment Tool Part No. HD-25070 Robinair Heat Gun Part No. HD-33416 Universal Driver Handle Part No. HD-33446A Cylinder Torque Plates Part No. HD-34731 Shoulderless Valve Guide Installation Tool Part No. HD-34623B Piston Pin Part No. HD-34643A Shoulderless Valve Guide Part No. HD-34740 Driver Handle and Remover. Use with Seal Installer Part No. HD-35457 Black Light Leak Detector Installer Part No. HD-35102 Wrist Pin Bushing Hone (20 mm) Part No. HD-35500A Digital Multi-Meter (FLUKE 23) Part No.HD-38125-8 Packard Terminal Crimp Tool Part No. HD-38361 Cam Gear Gauge Pin Set Needle Bearing Installer (0.108 in. (2.74 mm) Diameter) Part No. HD-38125-6 Packard Terminal Crimp Tool Part No. HD-39151 Shift Drum Retaining Ring Installer Part No. HD-39565 Engine Sound Probe Part No. HD-39617 Inductive Amp Probe. Part No. HD-39786 Cylinder Head Holding Fixture Part No. HD-39932 (Steel) or HD-39932-CAR (Carbide) Intake and Exhaust Valve Guide Reamer. Part No. HD-39800 Oil Filter Crusher, Small Part No. HD-41183 Heat Shield Attachment. Use with Part No. HD-25070. Part No. BU-44473 Tool Organizational System Part No. HD-41185 Hose Cutting Tool Part No. HD-41137 Hose Clamp Pliers Part No. HD-41185-1 Oil Hose Cutter-Replacement Blade Part No.
HD-42310-150 Drip Tray. Use with Part No. HD-42310. Part No. HD-41609 Amp Terminal Crimp Tool Part No. HD-41675 Oil Pressure Sending Unit Wrench Part No. HD-44358 Flywheel Support Fixture Part No. HD-42774 Sprocket Shaft Seal Installer Part No. HD-43682-10 Drip pan. Use with Part No. HD-43682 or Part No. HD-43646. Part No. HD-43646 Engine Stand Part No. HD-44069 Timkin Snap ring remover and installer. HD-94803-67 Intake Camshaft Bushing Reamer Remover. Use with Part No. HD-94547-102. Part No. HD-94547-102 Drive Handle. Use with Part No. Part No. HD-94804-57 Rocker Arm Bushing Reamer HD-94547-101. Part No. HD-94660-37B Mainshaft Locknut Wrench Part No. HD-95952-33B Connecting Rod Ring Pliers Clamping Tool Part No. HD-95635-46 All-Purpose Claw Puller Part No. HD-95970-32D Piston Pin Bushing Tool Part No. HD-95637-46A Wedge Attachment for Part No. HD-96215-49 Small Internal Retaining Claw Puller. HD-96796-47 Valve Spring Tester Part No. HD-96550-36A Valve Lapping Tool Part No. HD-96921-52B Oil Pressure Gauge Part No. HD-96710-40B Crankcase Main Bearing Part No. HD-96921-58 Oil Pressure Gauge Adapter. Lapping Tool Use with Part No. HD-97292-61 Two Claw Puller Part No. J-5586 Transmission Shaft Retaining Ring Pliers A-14 Appendix A: Tools. Female ends The following table provides a description of the connectors of connectors are labeled “B” in text.Three and eight pin connectors are of similar construction with one exception: eight pin connectors use two external latches on the socket side. NOTE Use the DEUTSCH TERMINAL CRIMP TOOL (Part No. HD- Pin housing 39965) to the fully open position.Pull apart the pin and socket halves. Bend back the latch slightly and free one side of second- ary lock, then repeat the step to release the other side. The tang in the chamber engages the slot to lock the ter- minal in position.
On the pin side of the connector, tangs are positioned at the bottom of each chamber, so the slot in the pin termi- nal (on the side opposite the crimp tails) must face down- ward. HD-41609) to the Raise locking bar and fully open position.Release locking tool.The fol- in this Service Manual are expressed in United States (U.S.) units-of-measure. Always clean around lines or covers before they are removed. Headlamp, passing lamp, tail lamp, brake lamp and turn Plug, tape or cap holes and openings to keep out dirt, dust signal operation. and debris. 2004 Buell P3: Maintenance. Part Replacement Bearings do not usually need to be removed. Only remove bearings if necessary. Always replace worn or damaged parts with new parts. 2004 Buell P3: Maintenance. Don’t pull on a tool cabinet; push it in front of you. Set the brakes on the locking casters after the cabinet has been rolled to your work. 2004 Buell P3: Maintenance. Drain the crankcase breather drain hose of any accumu- lated oil every time the oil is changed. 1-12 2004 Buell P3: Maintenance. Get medical attention for eyes.NOTE Repeat Steps 2-4 until all air bubbles are purged. Brake pedal has no freeplay adjustment. 1-14 2004 Buell P3: Maintenance. Excessive play or roughness indicates worn bearings. Replace bearings in A bump, bulge or split in the tire. sets only. Puncture, cut or other damage to the tire that cannot be repaired. 1-16 2004 Buell P3: Maintenance. 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. 2004 Buell P3: Maintenance 1-17. See Step 6 above. Figure 1-14. Adjusting Clutch Freeplay 12. Install left footpeg support bracket. See 2.21 FOOT- PEGS AND FOOTPEG SUPPORT BRACKETS. 1-18 2004 Buell P3: Maintenance. Primary Cover Figure 1-15. Remove three TORX screws with washers (1) from clutch inspection cover (2). Remove clutch inspection cover from primary cover. 2004 Buell P3: Maintenance 1-19.
Remove clutch inspection cover from primary cover. 12. Install seat. See 2.28 SEAT. 1-20 2004 Buell P3: Maintenance. Slide carrier with caliper off rotor. Remove left side spacer.Rear Axle, Right Side during vehicle operation and startle the rider, causing loss of control and personal injury. 28. Install seat. See 2.28 SEAT. 1-24 2004 Buell P3: Maintenance. ADJUSTMENT Figure 1-22. Buell Blast Models are shipped with a spacer between the primary chain limiting screw and the lock- nut. The spacer is used to quickly get proper adjustment dur- ing production.If the damper component is leaking or damaged it must be replaced. Bolt Damper bushing Damper component Stopper ring Spring seat Spring Spring seat stopper Figure 1-25. Rear Shock Absorber Assembly 1-26 2004 Buell P3: Maintenance. Removing Sub-Assembly Figure 1-27. Slider Tube Cap Figure 1-29. Remove the spring collar, lower spring joint and spring from slider tube. Figure 1-27. Remove slider tube cap. 2004 Buell P3: Maintenance 1-27. See Figure 1-31. Push down on spring seat past groove to install stopper ring. Stopper ring will lock into groove when installed correctly. 1-28 2004 Buell P3: Maintenance. NOTE Check that clutch and throttle cables do not bind when mea- suring bearing resistance. 2004 Buell P3: Maintenance 1-29. Fork Stem and Bracket Assembly 1-30 2004 Buell P3: Maintenance. Remove screw with spacer. Remove hex screw at bottom of air box (6 o’clock posi- tion) to release bracket from crankcase hole. 1-32 2004 Buell P3: Maintenance. Apply a small dab of Loctite 243 (blue) to threads of screw and install into remaining hole in venturi ring (2 o’clock position). Tighten screw to 18-22 in-lbs (2.0.-2.5 Nm). 2004 Buell P3: Maintenance 1-33. Throttle Cables 1-34 2004 Buell P3: Maintenance. Ignition coil cable Fuel supply valve Tachometer button Figure 1-44. Checking RPM Using a Hand Held Tachometer 1-36 2004 Buell P3: Maintenance.
Fuel supply - “RESERVE” position Once the fuel tank is completely drained, rotate han- Figure 1-45. Fuel Supply Valve dle of fuel supply valve to “OFF”.Push down on rear of seat until spring-loaded latch fully engages groove of seat pin. 1-38 2004 Buell P3: Maintenance. Transmission in neutral. Sidestand retracted.Main beam of light should be directed straight ahead (i.e. equal area of light to right and left of center). Adjust headlamp if necessary. See ADJUSTMENT. 1-40 2004 Buell P3: Maintenance. Leaking valves. 10. Water or dirt in fuel system and carburetor. Heavy carbon deposit. 11. Enrichener valve inoperative. 12. Air leak at intake manifold. Ignition timing retarded. 2004 Buell P3: Maintenance 1-43. Clutch plates excessively warped. Engine ground wire loose or broken. Loose or broken wires in charging circuit. Chatters Stator not functioning. Rotor not functioning. Friction or steel plates worn, warped, or dragging. 1-44 2004 Buell P3: Maintenance. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment, or luggage) tends to cause unstable han- dling. 2004 Buell P3: Maintenance 1-45. Damper tubes. Check for leaks. See 2.17 FRONT FORK. Shock absorber. Check damping action and mounts. See 2.15 REAR SHOCK ABSORBER. Swingarm bearings. Check for looseness. See 2.19 SWINGARM. 2004 Buell P3: Chassis. Loosen front axle nut (4). Loosen pinch screw (2). Remove front axle nut, spacer and washer. Pull front axle out of wheel hub while supporting front wheel. 2004 Buell P3: Chassis. Brake rotor bolt (5) 11. Brake rotor washer (5) 12. Front brake rotor 13. Washer Figure 2-6. Front Wheel Assembly 2004 Buell P3: Chassis. Move wheel forward and slide belt off. Measure rotor thickness. Replace if less than 4.5 mm. See 2.14 REAR BRAKE CALIPER. Check rotor surface. Replace if warped or badly scored. Inspect tire. See TIRES. 2004 Buell P3: Chassis 2-11. Right axle spacer 11. Lockwasher 12. Right axle spacer a0079x2x Figure 2-9.
Rear Wheel Assembly 2-12 2004 Buell P3: Chassis. Slide belt on sprocket teeth by rotating wheel to “walk” belt onto teeth. Lower motorcycle rear wheel. 2004 Buell P3: Chassis 2-13. Drop ball bearing inside collet (6). Fasten collet and ball bearing to forcing screw (1). Hold end of forcing screw (1) and turn collet (6) to expand edges of collet. 2-14 2004 Buell P3: Chassis. Figure 2-15. Place threaded rod through sup- port plate. Insert assembly through wheel.Installation Tool Support Plate 2004 Buell P3: Chassis 2-15. B-43993-1) 13. Threaded rod pilot (Part No. 280856) Figure 2-17. B-43933) 2-16 2004 Buell P3: Chassis. Checking Cast Rim Radial Runout using Wheel Truing and Balancing Stand (Part No. HD-99500-80) 2004 Buell P3: Chassis 2-17. Improper mounting can result in premature death or serious injury.If rim is dirty or corroded, clean with a stiff wire brush. Inspect tire for wear and damage. Replace worn tires. See. 2004 Buell P3: Chassis 2-19. Use front tire ONLY for a front tire. DO NOT put a rear tire on the front Position red dot at valve stem and starting 180 degrees of a vehicle. Allow eight hours for adhesive to cure completely before Install tire and check tire tread radial runout again.NOTE The individual parts of the brake lamp switch are not service- able. Replace switch upon failure. Remove two screws (1) (metric) and clamp (2) to detach master cylinder assembly from handlebar. 2-22 2004 Buell P3: Chassis. Front brake switch Figure 2-29. Front Brake Switch Figure 2-29. Remove screw, lockwasher and washer (1) holding front brake switch (3) to master cylinder assembly. Remove switch. 2004 Buell P3: Chassis 2-23. Replace housing if any of these conditions are found. Replace as necessary. 2-24 2004 Buell P3: Chassis. Lubricate pivot bolt (2) with LOCTITE ANTI-SEIZE. Install pivot bolt through top of assembly. Tighten to 4-13 in-lbs (0.5-1.5 Nm). Install nut (1) (metric). Tighten to 44-62 in-lbs (5- 7 Nm). 2004 Buell P3: Chassis 2-25.
Pin plug Mounting screws (2) Wireform Figure 2-37. Front Brake Caliper Figure 2-37. Remove banjo bolt (3) (metric) and two banjo washers (4) to disconnect brake line (1) from cali- per. Discard banjo washers. 2004 Buell P3: Chassis 2-27. Install pistons (2) in each piston bore. Install a new bleeder valve (metric) if necessary. Tighten to 36-60 in-lbs (4-7 Nm). 2-28 2004 Buell P3: Chassis. Tighten to 16-20 ft-lbs (22-27 Nm). Route brake line through wireform. 2004 Buell P3: Chassis 2-29. Apply brake hand lever to clamp (5) from right side of lower triple clamp. Remove test brake lamp operation. Turn ignition key switch to brake line from wireform. LOCK. 2004 Buell P3: Chassis 2-31. Screw (2) (metric Spacer (2) Piston assembly Rod assembly 10. Snap ring 11. Rubber boot 12. Locknut 13. Clevis 14. Clevis pin Figure 2-46. Rear Master Cylinder Assembly 2-32 2004 Buell P3: Chassis. Figure 2-47. Remove two screws (2) and spacers (3) to detach master cylinder from footrest support. 7703 Figure 2-48. Remote Reservoir Figure 2-48. Detach remote reservoir. 2004 Buell P3: Chassis 2-33. Depress piston into master cylinder body (1) and secure with a new snap ring (2). Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2-34 2004 Buell P3: Chassis. Snap ring 11. Rubber boot 12. Locknut 13. Clevis 14. Clevis pin Figure 2-53. Rear Master Cylinder Assembly 2-36 2004 Buell P3: Chassis. Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore. Discard o-rings. 2004 Buell P3: Chassis 2-37. Tighten to 132-180 in-lbs (15-20 Nm). Install pin plug. Tighten to 18-25 in-lbs (2-3 Nm). Tighten to 36-60 in-lbs (4-7 Nm). 2-38 2004 Buell P3: Chassis. Adjust linkage. 2-40 2004 Buell P3: Chassis. Rear Shock Absorber Assembly 2004 Buell P3: Chassis 2-41. Tighten to 12-17 in- lbs (1-2 Nm).Front Fork Assembly 2004 Buell P3: Chassis 2-43. Loosen headlamp bracket screws. 3765 Figure 2-65.
Upper and Lower Triple Clamp Pinch Screws Figure 2-65. Loosen the large pinch screws on both the upper and lower triple clamps. 2-44 2004 Buell P3: Chassis. Slider Tube Cap Spring Figure 2-70. Removing Sub-Assembly Figure 2-68. Remove slider tube cap. Figure 2-70. Remove the spring collar, lower spring joint and spring from slider tube. 2004 Buell P3: Chassis 2-45. Remove the center bolt (metric) from the bottom of the fork tube. 2-46 2004 Buell P3: Chassis. Removing Slider Tube 10. See Figure 2-75. Pull the slider tube out of the slider assembly. Remove oil seal, back-up ring and guide bush- ing. 2004 Buell P3: Chassis 2-47. Slider tube Components Figure 2-77. Check the slider tube for score marks, scratches and excessive or abnormal wear. Replace if worn or damaged. 2-48 2004 Buell P3: Chassis. Clamp the slider assembly in a vise with front fork holding tool (Part No. B-41177). Figure 2-80. Damper Assembly Figure 2-80. Install damper assembly and rebound spring into slider tube. 2004 Buell P3: Chassis 2-49. See Figure 2-86. Install guide bushing onto the slider tube. Figure 2-84. Install Rebound Spring Figure 2-84. Install spring onto damper assembly. 2-50 2004 Buell P3: Chassis. Verify ring is installed securely in the groove inside slider assembly. Figure 2-88. Oil Seal and Backup Ring 13. See Figure 2-88. Install oil seal spacer and backup ring. 2004 Buell P3: Chassis 2-51. Apply LOCTITE ANTI-SEIZE to the CALIPER.Align headlamp. See 1.23 HEADLAMP. 2004 Buell P3: Chassis 2-53. Capnut Center cap pinch screw Upper triple clamp Pinch screws (2) Dust shield (2) Bearing (2) Bearing cup (2) Lower triple clamp Pinch screws (2) Figure 2-99. Fork Stem and Bracket Assembly 2-54 2004 Buell P3: Chassis. Install the upper bearing (6) with small end down and 12. Install seat. See 2.28 SEAT. dust shield (5) onto fork stem. 2004 Buell P3: Chassis 2-55. Loosely install right side footpegs mount. 10. Install reservoir, master cylinder, and brake pedal.
Tighten brake pedal bolt to 72-96 in-lbs (8-11 Nm). 11. Tighten footpeg mounting bracket. 2-56 2004 Buell P3: Chassis. Failure to do so may result in corrosion of parts. NOTE Retaining ring may crack if not oriented as stated in step 3. 2004 Buell P3: Chassis 2-57. Bracket (2) Spacer 17. Grommet (2) Spacer, right Figure 2-101. Exhaust System Assembly 2-58 2004 Buell P3: Chassis. Oil tank drain hose Insert dowel pin (and on rear peg, spacer) through Breather hose mounting holes. Figure 2-103. Left Side Footpeg Support Bracket Install new cotter pin. 2004 Buell P3: Chassis 2-59. Install master cylinder bolts and spacers. See 2.13 REAR BRAKE MASTER CYLINDER. Bolts Spacers Pedal bolt Figure 2-104. Master Cylinder Mounting a0131x2x Screws (3) Nylon washers (3) Figure 2-105. Sprocket Cover Fasteners 2-60 2004 Buell P3: Chassis. Front Fender Assembly Mounting Screws Figure 2-106. Remove four lower fender mounting screws. 3804 Figure 2-107. Removing Front Fender Figure 2-107. Remove front fender. 2004 Buell P3: Chassis 2-61. Rear Fender Assembly Figure 2-108. Remove rear fender mounting screws and washers from rear fender. Remove rear fender. 2-62 2004 Buell P3: Chassis. Secure belt guard with two screws and nylon washers. Tighten screws to 30-36 in-lbs (3-4 Nm). Lower belt guard Screws (2) Nylon washers (2) Figure 2-109. Lower Belt Guard 2004 Buell P3: Chassis 2-63. Tail Section 2-64 2004 Buell P3: Chassis. Install brackets (12) and fasteners (13). Connect rear wire harness and mount on “T” stud. 2004 Buell P3: Chassis 2-65. Remove windscreen trim. Remove windscreen mounting brackets, if required. See 7.17 HEADLAMP. 2-66 2004 Buell P3: Chassis. Install dash with two mounting screws. Instrument Panel 2004 Buell P3: Chassis 2-67. Figure 2-115. Underside View of Seat with Locating Tab Verify seat is locked in position. 2-68 2004 Buell P3: Chassis. Without vehicle weight resting on it, sidestand should move freely into extended (down) and retracted (up) positions.
The sidestand activates the sidestand switch (4) which is part of the starter interlock system. 2004 Buell P3: Chassis 2-69. Left switch assembly 14. Right switch assembly 15. Throttle grip 16. Brake lever switch a0133x2x Figure 2-119. Handlebar Assembly 2-70 2004 Buell P3: Chassis. Front Isolator Bolts cle and death or serious injury. Install seat. See 2.28 SEAT. 2004 Buell P3: Chassis 2-71. If seat is loose, it could shift during vehicle operation, causing loss of control of vehi- cle and death or serious injury. Install seat. See 2.28 SEAT. 2-72 2004 Buell P3: Chassis. Frame-to-Isolator Bolts 7743 Rear isolator Bolts (4) Figure 2-123. Rear Engine Mount Isolator 2004 Buell P3: Chassis 2-73. Valve guide-to-valve stem clearance. The following are some general instructions that apply to Buell motorcycle engines: Gasket surface of both head and cylinder. 2004 Buell P3: Engine. For engine removal proceed to step 12. Figure 3-1. Remove Crankcase Breather Hose Figure 3-1. Remove crankcase breather hose and crankcase breather from rocker box grommet. 2004 Buell P3: Engine. See Figure 3-4. Remove top rear tie bar at frame. 2004 Buell P3: Engine. Use jack to lower motor. Breather hose Three-way connector 20. Move jack forward. 21. Place wooden cradle under engine. Figure 3-7. Crankcase Breather Hose 16. See Figure 3-7. Remove crankcase breather hose. 3-10 2004 Buell P3: Engine. Introduce freeplay and remove clutch cable at hand lever motorcycle. location. See 1.10 CLUTCH. 2004 Buell P3: Engine 3-11. Spark plug wire Located on spark plug. Battery—positive wire Disconnect at main circuit breaker.Removing Rear Motor Mount Bolts 32. See Figure 3-14. Remove rear motor mount bolts. Figure 3-12. Loosen Clamp 30. See Figure 3-12. Loosen nut on hose routing clamp. 2004 Buell P3: Engine 3-13. See Figure 3-18. Loosen swingarm pinch bolt. Figure 3-16. Air Cleaner Bracket 34. See Figure 3-16. Remove air cleaner box bracket. 3-14 2004 Buell P3: Engine. See Figure 3-19.
Remove swingarm pivot shaft and rear wheel as an assembly. See 2.19 SWINGARM. 2004 Buell P3: Engine 3-15. Figure 3-22. Swingarm Pivot Shaft Figure 3-22. Install swingarm, pivot shaft and rear wheel as an assembly and tighten pivot shaft to 24-26 ft- lbs (32-35 Nm). See 2.19 SWINGARM. 3-16 2004 Buell P3: Engine. Move Chassis to Engine few threads. Tighten to 30-33 ft-lbs (41-45 Nm). Figure 3-26. Roll chassis toward engine. Lift chassis onto engine. Raise lift. 2004 Buell P3: Engine 3-17. See Figure 3-30. Tighten hose clamps using Hose Clamp Pliers (Part No. HD-41137). 3-18 2004 Buell P3: Engine. Spark plug wire Located on spark plug. Battery—positive wire Disconnect at main circuit breaker.Apply several drops of LOCTITE 243 (blue) to last few threads. Tighten to 48-72 in-lbs (5-8 Nm). 3-20 2004 Buell P3: Engine. Right bracket to air cleaner, 36-60 in-lbs (4.1-6.8 Nm). Left bracket to crankcases, 120-144 in-lbs (13.6- 16.3 Nm). Install screw on air cleaner cover. 2004 Buell P3: Engine 3-21. See Figure 3-39. Install front tie bar onto engine. Apply several drops of LOCTITE 262 (red) to last few threads. Tighten to 30-33 ft-lbs (41-45 Nm). 3-22 2004 Buell P3: Engine. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-44. Rocker Arm and Push Rod Cover Assemblies 3-24 2004 Buell P3: Engine. Remove push rods. 2004 Buell P3: Engine 3-25. Remove valve, valve stem seal and lower collar assembly. Repeat the above procedure for the other valve. Figure 3-48. Valve Spring Compressor (Part No. HD-34736B) 3-26 2004 Buell P3: Engine. Cylinder base gasket 17. Cylinder base stud 18. Exhaust valve 19. Exhaust valve seat Figure 3-49. Cylinder Head, Cylinder and Piston Assembly 2004 Buell P3: Engine 3-27. HD-94804-57). Repeat for other end of rocker arm. 8733 8734 Figure 3-57. Replacing Rocker Arm Bushings 2004 Buell P3: Engine 3-31. HD-34751) and hot soapy water. B-45524) Cylinder head stand (Part No.
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