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SERVICE MANUAL
GENERAL 1.1
SERVICING A NEW MOTORCYCLE All special tools and torque v alues are noted at the point of
use.
All required parts or materials can be found in the appropriate
11
1WARNING
WARNING PARTS C ATALOG.
Replace bolts, nuts, studs, washers, spacers and small com- Inspect the bushing and the mated par t for oil holes. Be sure
mon hardware if missing or in any way damaged. Clean up or all oil holes are properly aligned.
repair minor thread damage with a suitable tap or die.
Gaskets
Replace all damaged or missing lubrication fitting .
Always discard gaskets after removal. Replace with new gas-
Use Teflon pipe sealant on pipe fitting threa . kets. Never use the same gask et twice. Be sure that gask et
holes match up with holes in the mating part.
Wiring, Hoses and Lines
Replace hoses, clamps, electr ical wir ing, electr ical switches Lip Type Seals
or fuel lines if they do not meet specification . Lip seals are used to seal oil or g rease and are usually
installed with the sealing lip f acing the contained lubr icant.
Instruments and Gauges Seal or ientation, however, may vary under diff erent applica-
Replace brok en or def ective instr uments and gauges . tions.
Replace dials and glass that are so scr atched or discolored Seals should not be removed unless necessary. Only remove
that reading is difficult seals if is necessar y to gain access to other par ts or if seal
damage or wear dictates replacement.
Bearings
Leaking oil or g rease usually means that a seal is damaged.
Anti-friction bear ings m ust be handled in a special w ay. To
Replace leaking seals to prevent overheated bearings.
keep out dir t and abr asives, co ver the bear ings as soon as
they are removed from the package. Always discard seals after remo val and replace with new
seals. Do not use the same seal twice.
Wash bear ings in a non-flamma le cleaning solution. Knock
out packed lubricant by tapping the bearing against a wooden O-Rings (Preformed Packings)
block. Wash bearings again. Cover bearings with clean mate-
rial after setting them down to dry. Never use compressed air Always discard O-r ings after remo val. Replace with new O-
to dry bearings. rings. To prevent leaks, lubr icate the O-r ings before installa-
tion. Apply the same type of lubr icant as that being sealed.
Coat bearings with clean oil. Wrap bearings in clean paper.
Be sure that all gask et, O-ring and seal mating surf aces are
thoroughly clean before installation.
Gears
Always check gears for damaged or worn teeth.
Lubricate mating surfaces before pressing gears on shafts.
Shafts
If a shaft does not come out easily , check that all n uts, bolts
or retaining r ings have been remo ved. Check to see if other
parts are in the way before using force.
Shafts fitted to tapered splines should be ery tight. If shafts
are not tight, disassemb le and inspect tapered splines . Dis-
card par ts that are w orn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mat-
ing parts together tightly.
Screwdrivers
TOOL SAFETY Dont use a scre wdriver for pr ying, punching, chiseling,
scoring or scraping.
Air Tools Use the right type of screwdriver for the job; match the tip
to the fastener.
Always use appro ved e ye protection equipment when Dont interchange POZIDRIV , PHILLIPS or REED
performing any task using air-operated tools. AND PRINCE screwdrivers.
On all po wer tools, use only recommended accessor ies Screwdriver handles are not intended to act as insula-
with proper capacity ratings. tion; do not use on live electrical circuits.
Do not exceed air pressure ratings of any power tools. Dont use a scre wdriver with rounded edges because it
Bits should be placed against w ork surf ace bef ore air will slip redress with a fil .
hammers are operated.
Ratchets and Handles
Disconnect the air supply line to an air hammer bef ore
attaching a bit. Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace par ts individually; ratch-
Never point an air tool at yourself or another person.
ets should be reb uilt with the entire contents of ser vice
Protect bystanders with approved eye protection. kit.
Sockets
Never use hand sockets on power or impact wrenches.
Select the right size socket for the job.
Never cock any wrench or socket.
Select only impact soc kets f or use with air or electr ic
impact wrenches.
Replace sockets showing cracks or wear.
Keep sockets clean.
Always use appro ved eye protection when using po wer
or impact sockets.
Storage Units
Dont open more than one loaded dr awer at a time .
Close each drawer before opening up another.
Close lids and loc k dr awers and doors bef ore mo ving
storage units.
Dont pull on a tool cabinet; push it in front of you.
Set the br akes on the loc king casters after the cabinet
has been rolled to your work.
1 1 1 1 2 2 2
ODOMETER READING 1 2 5 7 0 2 5 7 0 2 5
SERVICE OPERATIONS 0 5 0 5 0 5 0 5 0 5 0
(see chart code below) 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
mi mi mi mi mi mi mi mi mi mi mi
Change engine oil and filter (includes d aining crankcase breather hose) R I R I R I R I R I R
Inspect air cleaner and filter element, se vice as required I I
Change rear belt and rear sprocket R
Check clutch adjustment I I I I I I
Change transmission/primary chain case lubricant and clean drain plugSee R R R R R R
dealer
Check/adjust primary chain A A A A A A A A A A A
Inspect brake pad linings and discs for wear (front and rear) I I I I I I I I I I I
Change rear brake pads and rear brake pins R
Check brake fluid rese voir levels and condition I I I I I I
Check rear brake pedal operation I I I I I I
Inspect oil lines and brake system for leaks I I I I I I I I I I I
Lubricate front brake hand lever, throttle control cables, clutch control cables (and L L L L L
hand lever) and side stand
Lubricate and adjust steering head bearings X
Check operation and throttle control I I I I I I I I I I I
Inspect fuel valve, lines and fittings or leaks I I I I I I I I I I I
Clean fuel tank filter scree X
Check operation of all electrical equipment & switches including starter interlock I I I I I I I I I I I
Check battery and clean connections I I I I I I I I I I I
Change spark plug R R
Check tire pressure and inspect tread I I I I I I I I I I I
Check wheel bearings*
Change front fork oil X
Check stabilizer links and engine mounts I I
Check tightness of all critical fasteners: hand controls, brake system, axle nuts, T T
front fork components, riser and handle bar fasteners.
Check rear shock absorber I I
Check ignition timing I I
Check engine idle speed I I I I I I I I I I I
Inspect exhaust system hardware; including muffler st ap I I
Road test X X X X X X X X X X X
* Whenever wheel is removed (tire change, fork fluid chang , etc.)
NOTE:
See Table 1-1. The following codes are for the REGULAR MAINTENANCE INTERVALS Table:
I - Inspect & if necessary correct, clean or replace.
A - Adjust.
R - Replace or change.
T - Tighten to proper torque
L - Lubricated with specified lub icant
X - Perform
1 1 1 1 2 2 2
ODOMETER READING 1 2 5 7 0 2 5 7 0 2 5
SERVICE OPERATIONS 0 5 0 5 0 5 0 5 0 5 0
(see chart code below) 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
mi mi mi mi mi mi mi mi mi mi mi
Change engine oil and filter (includes d aining crankcase breather hose) R I R I R I R I R I R
Inspect air cleaner and filter element, se vice as required I I
Change rear belt and rear sprocket R
Check clutch adjustment I I I I I I
Change transmission/primary chain case lubricant and clean drain plugSee R R R R R R
dealer
Check/adjust primary chain A A A A A A A A A A A
Inspect brake pad linings and discs for wear (front and rear) I I I I I I I I I I I
Change rear brake pads and rear brake pins R
Check brake fluid rese voir levels and condition I I I I I I
Check rear brake pedal operation I I I I I I
Inspect oil lines and brake system for leaks I I I I I I I I I I I
Lubricate front brake hand lever, throttle control cables, clutch control cables (and L L L L L
hand lever) and side stand
Lubricate and adjust steering head bearings X
Check operation and throttle control I I I I I I I I I I I
Inspect fuel valve, lines and fittings or leaks I I I I I I I I I I I
Clean fuel tank filter scree X
Check operation of all electrical equipment & switches including starter interlock I I I I I I I I I I I
Check battery and clean connections I I I I I I I I I I I
Change spark plug R R
Check tire pressure and inspect tread I I I I I I I I I I I
Check wheel bearings*
Change front fork oil X
Check stabilizer links and engine mounts I I
Check tightness of all critical fasteners: hand controls, brake system, axle nuts, T T
front fork components, riser and handle bar fasteners.
Check rear shock absorber I I
Check ignition timing I I
Check engine idle speed I I I I I I I I I I I
Inspect exhaust system hardware; including muffler st ap I I
Road test X X X X X X X X X X X
* Whenever wheel is removed (tire change, fork fluid chang , etc.)
NOTE:
See Table 1-1. The following codes are for the REGULAR MAINTENANCE INTERVALS Table:
I - Inspect & if necessary correct, clean or replace.
A - Adjust.
R - Replace or change.
T - Tighten to proper torque
L - Lubricated with specified lub icant
X - Perform
GENERAL Washing
To wash molded-in-color panels follow the instructions below:
The purpose of this topic is to provide special care and main-
tenance instr uctions required f or the molded-in-color body Rinse surface with water.
panels that are standard on your Buell Blast P3 motorcycle. Wash with Harley Wash or Harley Sun Wash.
Molded-in-color surf aces look lik e painted surf aces, b ut are Rinse surface thoroughly with water.
not. The color pigment is mixed in with the mater ial when the
part is made , not applied o ver the surf ace. Molded-in-color Dry with a clean chamois or soft dry natural fiber cloth
panels require different maintenance than painted surfaces to
maintain their or iginal shine . Using methods that w ork on Cleaning Between Washings
painted surfaces may ruin the finish of molded-in-color pa ts. Untreated molded-in-color body panels sometimes ha ve a
static charge that attracts dust. Applying Harley Gloss or Har-
ley Glaze Polish and Sealant to molded-in-color surf aces will
CAUTION
eliminate this condition.
Use of abrasive pr oducts or po wered buffing equipmen To k eep a high gloss finish on molded-in-color panel
will cause permanent cosmetic dama ge to molded-in- between washings, follow the instructions below:
color body panels. Use only the recommended pr oducts
and tec hniques outlined in these instructions to a void Spray Har ley Gloss onto surf ace and wipe with a clean soft
damaging molded-in-color body panels. natural fiber cloth or Ha ley Softcloth.
NOTE
CAUTION Rain or water will remove Harley Gloss from body panels.
Do not use touch-up paint on molded-in-color panels. Reapply Har ley Gloss as descr ibed above to k eep surfaces
looking their best.
Harley Softcloth (Part No. 94656-98) Let Harley Glaze Polish and Sealant dry to a haze and buff off
residue with a clean soft cloth or Harley Softcloth.
BATTERY 1.4
(+)
11
1WARNING
WARNING Pad Pads (4)
CAUTION
11
1WARNING
WARNING
CAUTION
GENERAL
CAUTION
Check engine oil level (hot check): Do not s witch engine oil brands indiscriminatel y. Some
At every stop for fuel. oils interact c hemically when mix ed. Use of inf erior oils
or non-detergent oils can damage the engine.
Inspect oil lines and filter or leaks:
The motorcycle should be r idden for approximately 10 min-
At 1,000 mi (1,600 km) initial ser vice and e very
utes to ensure oil is hot and engine is at nor mal oper ating
2,500 mi (4,000 km) service interval.
temperature.
Change engine oil and filter (and d ain cr ankcase breather
hose) under nor mal ser vice in w arm or moder ate temper a-
tures:
At 1,000 mi (1,600 km) initial ser vice and e very a0075xox Dipstick
5,000 mi (8,000 km) service interval thereafter.
Change engine oil and filter (and d ain cr ankcase breather
hose) under se vere ser vice in w arm or moder ate temper a-
tures (severe dust, temperatures above 80oF/27oC, extensive
idling or speeds in e xcess of 65 mph/105 km/h, e xtensive
two-up riding):
At 1,000 mi (1,600 km) initial ser vice and e very
2,500 mi (4,000 km) service interval thereafter.
NOTE
Shorten oil change interval in cold weather.
Filler hole
CHANGING ENGINE
OIL AND FILTER a0074xox
3
2
4
CAUTION
GENERAL 7703
Every 2 years.
Figure 1-5. Rear Brake Fluid Reservoir
Inspect front and rear brake system fitting and lines or leaks:
Every 4 years.
Every 2 years.
Check rear brake pedal operation:
Bleeder Valve
See Figure 1-5. With motorcycle in a level position, check that
(metric)
brake fluid is bet een the upper and lo wer mar ks on front
and rear reser voirs. Add D.O.T. 4 BRAKE FLUID if neces-
sary. Be sure gasket and cap on reservoir fit securel .
BLEEDING BRAKES
11
1WARNING
WARNING
11
1WARNING
WARNING a0214x2x
Use onl y fresh, uncontaminated D .O.T. 4 Fluid. Cans of Brake fluid level
fluid that h ve been opened ma y ha ve been contami-
nated by moisture in the air or dir t. Use of contaminated
brake fluid m y adversely affect braking ability and lead
to brake failure whic h could result in death or serious
injury
11
1WARNING
WARNING
Use only new black banjo washers (See Parts Catalog for
Part No.) with D .O.T. 4 brake fluid Earlier silver banjo
washers are not compatib le with D .O.T. 4 fluid and wil
not seal pr operly o ver time . F ailure to compl y ma y
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
NOTE
Hydraulic brake fluid bladder-type pressure equipment can
be used to fill the brake master cylinder through the bleeder Figure 1-8. Brake Fluid Level - Front Reservoir
valve if master cylinder reservoir cover is removed to prevent
pressurization. 8. Attach covers to master cylinder reservoirs.
1. Install end of a length of plastic tubing o ver caliper a. Tighten screws on master cylinder reservoir cover to
bleeder v alve; place other end in a clean container . 9-13 in-lbs (1.0-1.5 Nm).
Stand motorcycle upright. b. Tighten cap on rear master cylinder securely.
a. See Figure 1-6. Front brake bleeder valve.
b. See Figure 1-7. Rear brake bleeder valve.
REAR BRAKE PEDAL
CAUTION
11
1WARNING
WARNING Friction
Material
Always replace brake pads in complete sets f or correct
brake operation. Never replace just one brake pad. Fail-
ure to install brake pads as a set could result in death or
serious injury.
See Figure 1-9. See Figure 1-10. Inspect br ake pads f or 1/16 in. (1.6 mm)
damage or excessive wear. Replace both pads as a set if fric- Minimum
tion material of either pad is worn to 0.04 in. (1.0 mm) or less.
If this amount of wear occurs, wear grooves (2) will disappear
Figure 1-9. Brake Pad - Side View
from friction material surface.
NOTE
11
1WARNING
WARNING
Do not allo w brake fluid bearing grease or other lubri- Figure 1-10. Measuring Rear Brake Outer Pad
cants to contact brake r otor or reduced braking ability
may occur, which could result in death or serious injury.
TIRE INFLATION
1-4. Tire Specifications/Pressure
Check front and rear tires f or proper inflation and inspec
SOLO LOADED
tread for cuts or punctures: P3 Tires
RIDING TO GVWR
Weekly, and at 1,000 mile (1,600 km) initial ser vice
Front 28 psi 32 psi
and at e very 2,500 mile (4,000 km) ser vice inter val
Dunlop 100/80 16 50s K330 (193 kPa) (220 kPa)
thereafter.
Rear 30 psi 36 psi
Dunlop 120/80 16 60s K330 (207 kPa) (248 kPa)
WHEEL BEARINGS
The wheel bear ings are sealed units , no greasing or mainte-
nance is required. Replace when w orn. Excessiv e pla y or
roughness indicates worn bearings that require replacement.
Check wheel bearings:
Whenever wheel is remo ved (tire change , f ork oil
change).
CLUTCH 1.9
GENERAL 11. Install left f ootpeg suppor t br acket. See 2.22 FOO T-
PEGS AND FOOTPEG SUPPORT BRACKETS.
Check clutch for proper adjustment:
At the 1,000 mile (1,600 km) initial ser vice and at
every 5,000 mile (8,000 km) service interval thereaf-
a0159x6x
ter.
Oil and adjust the clutch control cable: Rubber Boot
Every 5,000 miles (8,000 km) with LUBIT -8 TUFOIL
CHAIN AND CABLE LUBE (Part No. 94968-85TV). Cable End
GENERAL 7667
1
The tr ansmission should be dr ained and refilled with fres
fluid
INSPECTION
1. Remove seat. See 2.29 SEAT. 2 3
11
1WARNING
WARNING
To protect against shock and accidental star t-up of vehi- 1. Torx Screws with washers (3)
cle, disconnect the negative batter y cab le bef ore pr o- 2. Clutch Inspection Cover
ceeding. Inadequate saf ety precautions could result in 3. Magnetic Drain Plug (with O-ring)
death or serious injury.
2. Disconnect negative battery cable from battery. Figure 1-14. Primary Cover