Engine:
Complete overhaul, diagnosis, adjustments, component testing, lubrication, cooling system, fuel system (carburetor and injection depending on specific model variants within the range), ignition system, exhaust system.
Transmission:
Clutch operation, gearbox disassembly and assembly, lubrication, troubleshooting.
Chassis:
Frame inspection and repair, front suspension (forks, steering head), rear suspension (shock absorber, swingarm), wheel bearings, steering components.
Brakes:
Hydraulic system (master cylinders, calipers, lines), brake pad replacement, rotor inspection, bleeding procedures.
Electrical System:
Wiring diagrams, charging system (alternator, regulator/rectifier), starting system (starter motor, battery), lighting system, instrumentation, ignition coil, sensors, ECU troubleshooting.
Fuel System:
Fuel tank, fuel pump, fuel lines, carburetor (if applicable), fuel injection system components (injectors, regulator).
Bodywork:
Fairing removal and installation, seat, fenders, minor body panel repairs.
Exhaust System:
Removal, installation, inspection of mufflers and headers, emissions control components (if applicable).
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing procedures.
Frame And Swingarm:
Inspection for cracks or damage, swingarm bearing service, frame-related bolt torques.
Cooling System:
Air-cooled engine, but manual may cover any oil cooling components if present.
Maintenance:
Scheduled maintenance intervals, oil and filter changes, chain adjustment, spark plug replacement, air filter service, brake fluid replacement, coolant checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable), symptom-based troubleshooting guides.
Repair:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Adjustments:
Carburetor tuning, clutch adjustment, throttle cable adjustment, suspension setup, idle speed adjustment.
Overhaul:
Detailed procedures for complete engine disassembly, inspection, and reassembly, including critical tolerances and torque specifications.
Wiring Diagrams:
Comprehensive electrical schematics with component identification and wire colors.
Depth:
Comprehensive, covering basic to advanced repair and overhaul procedures, including detailed diagnostic information and factory specifications.
Diagnostic Tools:
References special service tools required for specific adjustments and repairs, with accompanying diagrams showing tool usage.
Specifications Lists:
Includes comprehensive lists of service data, specifications, tightening torques, wear limits, and allowable tolerances for all major components and systems.
Pictorial Diagrams:
Features detailed illustrations, exploded diagrams, drawings, and photographs to guide through service and repair procedures.
Type:
Air-cooled, 45-degree V-twin, pushrod actuated OHV
Displacement:
1200cc (approx. 73.3 cubic inches)
Bore X Stroke:
3.49 x 4.25 inches (88.6 x 108 mm)
Cylinder Head:
Pushrod-actuated overhead valves, two valves per cylinder.
Horsepower:
Approx. 101 hp @ 6000 rpm (varies slightly by year/spec)
Torque:
Approx. 84 ft-lbs @ 4800 rpm (varies slightly by year/spec)
Compression Ratio:
Manual will provide specific compression ratio values for engine tuning and diagnostics.
Carburetion:
Mikuni BDSR40 (common on S3 models, although some later S3T may have had fuel injection)
Fuel Type:
Unleaded gasoline, minimum 91 octane (87 AKI)
Fuel Pump Type:
Electric (location and type detailed in manual).
Oil Type:
Buell recommends specific motorcycle-specific synthetic or semi-synthetic oil (e.g., Buell/Harley-Davidson lubricants). Manual will detail viscosity and API classification.
Oil Change:
Typically every 3,000-5,000 miles or annually. Manual will provide precise intervals based on usage and conditions.
Valve Adjustment:
Refer to manual for specific mileage intervals, often around 6,000-10,000 miles.
Belt Tension Check:
Regular checks are critical, typically every oil change. Manual will specify proper tension and adjustment procedure.
Brake Fluid:
DOT 4 recommended. Manual will specify exact type and replacement intervals.
Coolant:
N/A (Air-cooled engine)
Fork Oil:
Manual will specify the type and quantity of fork oil required for front suspension service.
Common Problems:
Potential for cam chain tensioner wear, occasional electrical gremlins, stator failures (common on many V-twins of this era), and carburetor synchronization issues.
Preventative Maintenance:
Regular inspection of cam chain tensioners, ensuring proper electrical connections, and keeping the carburetor meticulously clean and synchronized are crucial.
Common Repairs:
Addressing oil leaks from gaskets, rebuilding carburetors, and servicing the clutch slave cylinder are common repair tasks covered.
