🏷️ Basic Information

Make:

Buell

Model:

Thunderbolt S3T

Years Covered:

1999, 2000, 2001, 2002

👋 Introduction

Segment:

Performance Sportbike

Competitors 1999-2002:

Ducati Monster series, Triumph Speed Triple, Yamaha YZF600R (as a sport-tourer), Suzuki TL1000S.

Design Philosophy:

Unique American sportbike design, combining Harley-Davidson V-twin power with a European-influenced chassis and sporting intent.

S3T Distinction:

The 'T' designation typically indicated a 'Touring' or 'Tall' variant, potentially featuring a larger fairing, comfortable seating, or other touring-oriented amenities compared to the standard S3.

📋 Manual Details

Primary Coverage:

Workshop Service and Repair

Total Pages:

458

Type:

Service Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Detailed disassembly, assembly, inspection, and repair of the Buell V-Twin engine (likely Harley-Davidson Evolution Sportster derivative), including cylinder heads, cylinders, pistons, crankshaft, camshafts, valve train, and lubrication system.

Fuel System:

Carburetor (likely Mikuni HSR42 or similar), fuel pump, fuel lines, fuel tank, and associated components, including diagnosis and adjustment procedures.

Ignition System:

Ignition module, coils, spark plugs, wiring, and troubleshooting for optimal spark delivery.

Transmission:

5-speed transmission, clutch assembly, primary drive, secondary drive (belt drive), and associated maintenance and repair procedures.

Brakes:

Front and rear brake systems, including caliper service, master cylinder overhaul, brake line replacement, fluid bleeding, and troubleshooting.

Suspension:

Front forks (likely Showa or Marzocchi) and rear shock absorber, including fork seal replacement, oil changes, and suspension adjustments.

Electrical System:

Comprehensive coverage of wiring diagrams, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, switches, and troubleshooting electrical faults.

Chassis And Frame:

Frame inspection, component mounting, and general chassis maintenance.

Bodywork And Fairings:

Removal, installation, and repair of body panels, fairings, and associated trim components.

Wheels And Tires:

Wheel bearing maintenance, tire mounting and balancing, and related checks.

Routine Maintenance:

Oil and filter changes, spark plug replacement, chain/belt adjustment, air filter service, brake fluid checks, and general lubrication.

Troubleshooting:

Detailed diagnostic procedures for common and complex issues, including symptom-based troubleshooting guides.

Repair And Rebuild:

Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.

Adjustments:

Carburetor synchronization and adjustment, clutch adjustment, chain/belt tension adjustment, suspension settings, and throttle cable adjustment.

Installation Removal:

Procedures for removing and installing major components and sub-assemblies.

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including diagnostic information and specifications.

Detail Level:

Includes detailed step-by-step procedures, pictorial diagrams, exploded views, and photographs to guide the user.

Special Tools:

References and illustrations for required special service tools.

Torque Specifications:

Inclusion of all necessary torque values for critical fasteners.

Wear Limits:

Provides specific wear limits and tolerances for critical engine and chassis components.

📊 Manual Specifications

Compatibility:

Windows, Mac, Linux OS

Requirement:

Adobe Reader

Printability:

Yes, all pages are printable.

Digital Format:

Instant Download PDF

Digital Quality:

High-resolution digital scans, ensuring clarity of text and images.

⚙️ Engine Specifications

Type:

Air-cooled, 45-degree V-twin, pushrod-actuated OHV

Displacement:

1200 cc (73.2 cubic inches)

Horsepower:

Approximately 101 hp (actual may vary slightly by year/tune)

Torque:

Approximately 85 ft-lbs (actual may vary slightly by year/tune)

Carburetor:

Mikuni HSR42 (common specification, manual will confirm exact model)

Ignition Type:

Electronic Ignition (CDI or similar)

Oil Type Spec:

Refer to manual for specific viscosity (likely SAE 20W50 motorcycle oil) and API classification.

🔧 Transmission

Type:

5-speed constant mesh

Primary Drive:

Gear to gear (straight-cut gears within primary cover)

Secondary Drive:

Belt drive (Enclosed belt system)

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil Spec:

Refer to manual for specific viscosity and type (typically a dedicated motorcycle transmission oil).

📐 Dimensions

Wheelbase:

Approx. 57.5 inches (1460 mm)

Dry Weight:

Approx. 490 lbs (222 kg)

Fuel Capacity:

Approx. 4.5 gallons (17 liters)

🛡️ Safety Features

Braking System:

Dual front disc brakes with 4-piston calipers, single rear disc brake with 2-piston caliper. Potential for early ABS depending on specific market/options, but not standard on all models.

Frame Design:

High-tensile steel frame with integrated oil reservoir in the frame backbone.

💡 Technology Features

Dashboard:

Analog tachometer, speedometer, odometer, trip meter, and indicator lights. Focus is on essential rider information.

ABS:

Optional on some models, but not standard across the board. Manual will detail if ABS components are present and their service requirements.

Smartphone Integration:

Not applicable for this era of motorcycle.

🔧 Maintenance

Engine Oil Change:

Refer to manual for specific mileage/time intervals, typically around 3,000-5,000 miles or annually.

Spark Plug Replacement:

Refer to manual for specific mileage intervals, typically around 7,500-10,000 miles.

Belt Tension Check Adjust:

Regular checks, typically every 3,000-6,000 miles, with specific tension specifications in the manual.

Brake Fluid Flush:

Recommended every 2 years or as per manual's fluid change schedule.

Engine Oil:

Consult manual for precise SAE viscosity grade (e.g., 20W50) and API classification. Many Buells use a blended oil or a specific motorcycle-specific oil with wet clutch compatibility.

Transmission Oil:

Consult manual for precise viscosity and type. Often shares engine oil or requires a specific gear oil.

Brake Fluid:

DOT 4 is standard for most motorcycles of this era. Manual will specify exact type.

Electrical Connections:

Corrosion or poor connections in the electrical system can lead to intermittent faults. The manual's wiring diagrams and troubleshooting sections are crucial.

Belt Drive Tension:

Improper belt tension can lead to premature wear or failure. Regular checks and adjustments are vital.

Carburetor Tuning:

Achieving optimal carburetor performance may require periodic adjustments and cleaning, especially given the performance-oriented nature of the HSR42.

Suspension Seals:

As with many bikes of this age, fork seals and rear shock seals can degrade over time, requiring replacement.

📚 Vehicle History

Founder:

Erik Buell, known for innovative chassis and sportbike performance.

Thunderbolt Lineage:

The Thunderbolt S3T was an evolution of the earlier Cyclone and Thunderbolt models, evolving from the M2 Cyclone and S2 Thunderbolt. It represented Buell's attempt to create a more versatile sport-touring machine utilizing the powerful V-twin.

Manufacturing Location:

East Troy, Wisconsin, USA

Ownership Era:

Produced during the period of Harley-Davidson ownership of Buell Motorcycle Company.

🏆 Awards & Recognition

Market Reception:

While specific awards might be scarce, Buell motorcycles of this era were recognized for their unique styling, powerful V-twin engines, and agile handling, appealing to enthusiasts seeking something different.