Engine Mechanical:
Full disassembly, assembly, inspection, and repair of the engine and its sub-components.
Fuel System:
Fuel injection system, fuel pump, injectors, fuel lines, and related components.
Ignition System:
Ignition coils, spark plugs, wiring, and ignition control module.
Cooling System:
Oil cooling system (Buell's typical setup), oil lines, oil pump, oil filter, and oil cooler.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, final drive belt system (tensioning, inspection).
Frame Chassis:
Frame inspection, swingarm removal and installation, steering head bearings.
Suspension Front:
Front fork disassembly, assembly, oil changes, seal replacement, and adjustment procedures.
Suspension Rear:
Rear shock absorber removal, installation, and adjustment procedures.
Brakes Front:
Brake caliper overhaul, master cylinder service, brake line replacement, pad replacement.
Brakes Rear:
Rear brake caliper overhaul, master cylinder service, brake line replacement, pad replacement.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation.
Bodywork Fittings:
Fairing removal and installation, seat, handlebars, footpegs, and other external components.
Routine Maintenance:
Oil changes, filter replacements, chain/belt adjustments, brake checks, fluid level checks, spark plug replacement.
Disassembly Assembly:
Detailed step-by-step instructions for removing and reinstalling all major components and sub-assemblies.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, including symptoms and potential causes.
Adjustments:
Precise instructions for calibrating engine components, suspension, brakes, and electrical systems.
Torque Specifications:
Specific torque values for critical fasteners across all systems, ensuring proper assembly and safety.
Wear Limits:
Specified acceptable wear limits for various components, enabling accurate assessment of part condition.
Special Tool Usage:
Identification and usage instructions for specialized tools required for specific repair operations.
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds.
Pictorial Support:
Abundant detailed illustrations, exploded diagrams, and photographs to guide users through procedures.
Engine Type:
Air-cooled, 45-degree V-twin, Thunderstorm OHV
Displacement:
984 cc (60 cu in)
Bore X Stroke:
3.49 in x 3.25 in (88.9 mm x 82.5 mm)
Compression Ratio:
9.2:1 (typical for the era and model)
Valve Train:
OHV, 2 valves per cylinder, pushrod actuated
Horsepower:
Approximately 92 HP (at crankshaft, specifications may vary)
Torque:
Approximately 70 ft-lbs (at crankshaft, specifications may vary)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended
Oil Type:
Refer to manual for specific viscosity and API classification (e.g., Harley-Davidson Genuine V-Twin Motorcycle Oil or equivalent SAE 20W-50)
Oil Capacity:
Refer to manual (typically around 3 quarts / 2.8 liters including filter)
Oil Change Interval:
Refer to manual for specific mileage/time intervals (typically 2,500-5,000 miles or annually).
Belt Tension Check:
Refer to manual for specific intervals.
Spark Plug Replacement:
Refer to manual for specific intervals.
Engine Oil:
Refer to manual for specific viscosity and API classification (e.g., SAE 20W-50, Harley-Davidson spec).
Brake Fluid:
DOT 4 recommended.
Transmission Fluid:
Refer to manual for specific gear oil specifications.
Common Points:
Electrical connectors, fuel sensor issues, belt drive wear, vibration at certain RPMs (typical for V-twins).
Preventative Measures:
Following scheduled maintenance, using quality parts and fluids, thorough inspection of wiring and connections.
Affiliation:
Originally associated with Harley-Davidson
Introduction Era:
Early 2000s, building upon Buell's sportbike heritage with a more streetfighter-oriented model.
Design Philosophy:
Known for its unique engineering, including the frame as an oil tank, Uniplanar engine mounting, and perimeter front brake rotor.
Manufacturing Location:
East Troy, Wisconsin, USA
