2001 Buell S3 S3T Thunderbolt Workshop Service Repair Manual

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Type: Motorcycle

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Sku: 134630

Tags: 2001 Buell Motorcycle Motorcycles S3 S3T Thunderbolt Thunderbolt

Product variants

Description

Welcome to the comprehensive guide for the 2001 S3 Thunderbolt and S3T Thunderbolt motorcycles. These American-made sport-touring machines, produced in East Troy, Wisconsin, are renowned for their innovative engineering, including a signature frame-as-oil-tank design and under-engine exhaust systems, which contribute to exceptional handling and mass centralization. Powered by a 1203 cc V-Twin engine, these models offer a potent blend of performance and touring capability, making them a unique choice for riders seeking a distinct riding experience. This workshop service repair manual provides detailed information essential for the maintenance, repair, and understanding of your 2001 S3/S3T Thunderbolt. It covers critical areas such as general maintenance, chassis, engine, fuel system, starter system, drive/transmission system, and electrical system. Within these sections, you will find step-by-step procedures for component removal and installation, complete disassembly and reassembly, electrical diagnostics, wiring diagrams, and troubleshooting guides, all presented with detailed technical specifications and torque values to assist owners and professional technicians alike.

🏷️ Basic Information

Identification

Make:

Buell

Model:

S3 Thunderbolt

Model Variant:

S3T Thunderbolt

Year:

Codes

Vin Prefix:

👋 Introduction

Market Position

Target Audience:

Owners of the 2001 Buell S3/S3T Thunderbolt seeking to perform maintenance, repairs, and gain a deeper understanding of their motorcycle.

Competitive Analysis

Manual Advantage:

Provides factory-level repair information in a convenient digital format, offering significant cost savings compared to authorized dealer service.

Key Features

Key Features:

Instant download, high-quality diagrams, comprehensive coverage, printable pages, cross-platform compatibility.

📋 Manual Details

Coverage Areas

Manual Coverage Summary:

Comprehensive service, repair, and maintenance information for the 2001 Buell S3 and S3T Thunderbolt motorcycles.

Page Count

Estimated Page Count:

Not specified, but typically 300-500 pages for such a comprehensive manual.

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Systems Covered:

Maintenance, Chassis, Engine, Fuel System, Starter System, Drive/Transmission System, Electrical System.

Procedures Included

Procedures Included:

General maintenance, lubrication, adjustments, troubleshooting, component removal and installation, complete disassembly and reassembly, electrical diagnostics, wiring diagrams.

Technical Depth

Technical Depth:

Detailed diagnostic procedures, repair techniques, specifications, torque values, and component testing for DIY enthusiasts and professional technicians.

📊 Manual Specifications

File Format

Compatibility:

All Versions of Windows & Mac

Reader Requirement:

Adobe PDF Reader

Print Quality

Printability:

All pages are printable.

Binding Type

Binding Type:

Digital Download (no physical binding)

Paper Type

Paper Type:

N/A (Digital File)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-Twin, Four-Stroke

Displacement:

1203 cc (73.4 cubic inches)

Bore X Stroke:

88.9 mm x 96.8 mm (3.50 in x 3.81 in)

Compression Ratio:

9.0:1 (Typical for this era and engine)

Valve Train:

OHV, 2 valves per cylinder

Cooling System:

Air-cooled

Ignition System:

Electronic Ignition (Specifics like dwell angle and timing are in the manual)

Performance

Horsepower:

Approximately 91 hp @ 6600 rpm (Manufacturer claimed, actual may vary)

Torque:

Approximately 78 ft-lbs @ 5200 rpm (Manufacturer claimed, actual may vary)

Fuel System

Fuel Delivery:

Fuel Injection (Specifics on injectors and fuel pump are detailed)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Features

Clutch Type:

Wet, Multi-plate

Final Drive:

Chain Drive

📐 Dimensions

Exterior

Overall Length:

Approximately 85 inches (specifics vary slightly between S3 and S3T)

Overall Width:

Approximately 32 inches (handlebar width)

Seat Height:

Approximately 30.5 inches

Weights

Dry Weight:

Approximately 475 lbs (S3), 490 lbs (S3T)

Gross Vehicle Weight Rating:

Not specified, consult manual for rider/cargo limits.

🛡️ Safety Features

Ratings

Crash Test Results:

Motorcycle safety is not rated by traditional crash test agencies like automotive.

Active Features

Braking System Front:

Dual Disc, 320 mm diameter, 6-piston calipers (Buell DDL - Ductal Disc Rotor)

Braking System Rear:

Single Disc, 230 mm diameter, 2-piston caliper

Passive Features

Suspension Front:

41mm Showa Upside-Down Fork (with adjustable preload, compression, and rebound damping)

Suspension Rear:

Monoshock, Showa, Adjustable preload and damping

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer, digital speedometer, odometer, trip odometer, fuel gauge, engine temperature indicator.

Driver Assistance

ABS Availability:

Optional on some models, but not standard on the 2001 S3/S3T.

Connectivity

Bluetooth Connectivity:

Not applicable for this model year.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or annually, whichever comes first (Refer to manual for exact recommendation).

Spark Plug Replacement:

Typically every 10,000-15,000 miles (Consult manual for specific plug type and gap).

Chain And Sprockets Inspection:

Regular inspection and lubrication every 500-1000 miles, adjustment as needed.

Fluid Specifications

Engine Oil Type:

Buell recommends Harley-Davidson 20W50 motorcycle oil, or equivalent (API SG or higher).

Engine Oil Capacity:

Approximately 3.0 US quarts (2.8 liters) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Primary Chaincase Lubricant (or suitable equivalent).

Transmission Oil Type:

Harley-Davidson Transmission Lubricant (or suitable equivalent).

Brake Fluid Type:

DOT 4 (or DOT 5.1 if specified for higher boiling point).

Known Issues

Common Buell Issues:

Oil leaks (especially around cylinder base gaskets and rocker boxes), stator failures, electrical connector corrosion, Buell Race Kit tuning can be sensitive. Frame-mounted oil bag maintenance.

Thunderbolt Specific Issues:

Fairing vibration at certain RPMs, potential for wear in the swingarm pivot bearings, clutch cable adjustment sensitivity.

📚 Vehicle History

Brand Heritage

Brand Foundation:

Buell Motorcycle Company was founded by Harley-Davidson engineer Erik Buell, focusing on sportbikes with innovative chassis technology.

Model Evolution

Thunderbolt Lineage:

The S3 Thunderbolt was part of Buell's sport-touring lineup, evolving from earlier models like the RR and RS series, incorporating the Harley-Davidson Sportster engine.

Production

Production Period:

The Thunderbolt series was produced from the mid-1990s until Buell's closure in 2009. The S3 model was produced from 1995-2002.

Manufacturing Location:

East Troy, Wisconsin, USA

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Buell motorcycles are recognized for their unique engineering, including the frame-as-oil-tank and under-engine exhaust designs, contributing to excellent handling and mass centralization.