B-033A. Safety Recall Code 0820
Contents
1. NOTE Quantity and part numbers may vary depending upon what you have in stock Upon receipt of properly completed claim for parts in dealer stock you will receive the appropriate credit for parts Buell Distribution Corporation will advise at a later date how to order updated shock absorbers to replenish your stock Do not order the recall kits to restock your inventory 5of5 0v0l 4 VSN NI sajes II u uo Ajdde yey sexe 290 pue lelS Teepe Ne Jo JuaWAed pue uono lloo 10 lqisuods aq II JeSBYOIN eles JO SSO 104 seBeWeP p lepinbii se awy o awn wos GaLNidd oyod uedwog q p uluu l p se aoud Buas Jo 1ueo1 d AJ Quew 10 Us o1 z snid ulIw i u p jbp uuo5 S09 OUS eu Aed IIeus 1 seuoind ll s o spooB Jo WNAI 10 1u tuuBisuoo Jo ased u pue lu uidius JO yep ul o 1oltud 1 ll s q p AI 5 1 q Jsnw joalay Wed Aue 10 1 pio Sty JO uonieli 9ueo 1oj Jsanbal Auy J All p 0 re 10 uswidiys u Aejap o anp ewep 10 ssoj Aue 104 l qe i q 1ou eys 1 ll s pue 1 p10 p d oo SADNSAGNOdSs3YYOO ADNSAGNOdSsYyYOO H04 3SN LON OG ane ae tants oe pio alse BAIN ai eens ss iq i ae eee eae Hod ASN LON Od SYASSINNN LYVd 3SN ASV4A 1d LOZES IM ASMNVMIIW LY SONVLda9OV OL LOArANS SHAGHO T1V SHSSINNN LYVd JSN ASV4A 1d ISuodse jo 1 seuoind enaljou Jou ieys 1u uudius UI el p uy JeseyoINd 0 I ANJ P 104 19l s 0 spoo6 1 uloue ywuqns es2. DEALER ACTION AFFECTED VEHICLES Recently Buell Distribution Corporation sent a complete list of all vehicles shipped to your dealership involved in this recall To ensure the safety of all affected riders it is your responsibility to perform the required service on all affected vehicles even if the motorcycle was not purchased from your dealership If you are not sure that a safety recall has been completed on a particular Buell motorcycle contact the recall information line at 1 800 448 1708 Recall information is also available on TALON and hd net com IMPORTANT NOTE Because only registered owners received notification from Buell Distribution Corporation we request that you contact any owners of vehicles previously listed as unregistered Advise them of the safety recall and make arrangements for them to come in for recall service We also require that you provide us with their names addresses and V I N s as soon as possible This will enable us to mail them an owner s letter as required by National Traffic and Motor Vehicle Safety Act as amended Kits must be ordered as required and will be available on or before December 18 2000 Use inventory of original recall kits until exhausted Once exhausted the original kits will supersede to the revised kits listed in this bulletin To order kits please fill out the attached order form and send fax it to the Warranty Department at FAX 414 343 8346 All kits will be shipped n
3. 9 Test ride motorcycle 10 Provide customer with Customer Instructions for Shock Replacement and Adjustment Instruction Sheet Number J01561 provided in kit 4of5 B 033A CREDIT PROCEDURE For each vehicle serviced place a C in the letter box on the Buell Dealer Service Card Send the properly completed dealer service cards to Buell Distribution Corporation 3700 W Juneau Ave Milwaukee WI 53208 Upon receipt and pro cessing of your properly completed dealer service cards you will be credited for 0 6 hours labor for M2 S3 and S3T Mod els and 0 7 hours labor for X1 Models All times include 0 1 hour administrative time No credit will be issued for the kits as they were sent no charge transportation paid B 033A CREDIT PROCEDURES DEALER STOCK PARTS Remove all affected shock absorbers Part Nos listed below from your inventory To receive credit complete a regular war ranty claim referencing Service Bulletin B 033A in the Description of Repair section Fill in the rest of the claim as follows Credit for Parts Claim Type BDS Event 1 Problem Part No 93925Y or 54620 99Y M2 Recall or OE Shock Absorber Part Description Event 2 Problem Part No 93930Y or 54622 99Y S3 S3T Recall or OE Shock Absorber Part Description Event 3 Problem Part No 946217991 Part Description X1 OE Shock Absorber Customer Concern Code 9205 Condition Code 9111
4. 8 Position front clamp over reservoir Loosely install new front reservoir clamp to front shock mount with new washer and new nylon locknut 9 See Figure 3 Loosely install new rear clamp around res ervoir and oil feed line 10 All Models Install new reservoir mount block between oil pump fitting and remote reservoir 11 Tighten front shock mounting hardware to 40 45 ft lbs 54 2 61 0 Nm Tighten rear shock mounting hardware to 30 33 ft lbs 41 45 Nm 12 Tighten clamps around reservoir 13 X1 Models Only Install chin fairing using new wellnut See Section 2 of X1 Service Manual for procedure NOTE If installing new swing arm from 0816 recall stop procedure here and see ADJUSTMENT on following page when swing arm installation is complete If not installing new swing arm continue with Step 14 below 14 Lower and remove jack from under swing arm mount block 15 Connect negative battery cable Tighten to 40 in Ibs 4 5 Nm 16 Set preload See ADJUSTMENT 17 Test ride ADJUSTMENT 1 See Figure 4 Check and adjust rear shock preload a With rider seated on motorcycle the preload is determined by measuring the distance between the centers of the front and rear shock eye and adjust ing until the measurement is within specification b See below for optimum preload measurements e All Models 15 2 15 5 in 386 394 mm B 033A Preload Measurement Rider Seated on Motorcycle All Models 1
5. 5 2 15 5 in 386 394 mm Figure 4 Measuring Preload He amp b00851x2x Compression Adjuster Slotted Dial Locknut 65 72 ft lbs Z 88 98 Nm Preload Adjuster Figure 5 Preload and Compression Damping Adjustment Rebound Adjuster Slotted Dial Figure 6 Rebound Adjustment NOTE e All measurements must be taken with rider seated on motorcycle e Riders with passenger at or near GVWR may exceed optimum preload adjustment 3of5 2 See Figure 5 To adjust shock preload loosen the lock nut and turn the preload adjuster at the end of the shock to move can towards front or rear of motorcycle TOP VIEW lt b0921x2x a Tighten adjuster move can towards rear of motorcy Fear of Motorcycle New cle to increase preload i b Loosen adjuster move can towards front of motor cycle to decrease preload a oe eee eee Ha BP 3 See Figure 7 When finished apply wheel bearing ne E grease halfway around the shock 180 degrees to the mating faces of the locknut and adjuster nut and the first few threads on the aluminum body leading to the RLA adjuster nut a Locknut Adjusting 4 Thread locknut back into place Grease Nut NOTE Apply grease to shaded areas halfway around shock to mating faces of nuts and to leading threads Torque wrench and crows foot must b
6. SERVICE BULLETIN Buell B 033A December 4 2000 AMERICAN MOTORCYCLES SAFETY RECALL CODE 0820 NEW SHOCK ABSORBER GENERAL Buell Motorcycle Company has learned that certain 1999 and 2000 Buell motorcycles were built with a rear shock absorber that could break If the shock should break the underside of the vehicle could drag on the ground which may adversely affect handling and could cause an accident Accordingly Buell Motorcycle Company is voluntarily conducting a recall campaign to formally recall all potentially affected motorcy cles This campaign involves all 1999 M2 Cyclone and all 2000 X1 Lightning M2 Cyclone S3 Thunderbolt and S3T Thunderbolt model Buell motorcycles manufactured between January 5 1998 and May 31 2000 This condition was initially remedied by installing a shock reinforcement package SRP on all potentially affected vehi cles Since the release of the original bulletin B 033 Buell Motor cycle Company has released a new shock absorber that pro vides the same benefits as the original SRP kit This new shock absorber installation should be performed in lieu of the SRP installation on all affected models once you have used up your stock of SRP kits This revised recall procedure applies to affected motorcycles that did not have the initial 0820 recall service performed For motorcycles that have had the original 0820 recall service performed obtain a fac tory authorization to replace the shock
7. able lift ROUTING SERVICE MANAGER SALES MANAGER PARTS MANAGER LEAD TECHNICIAN TECHNICIAN NO 1 TECHNICIAN NO 2 TECHNICIAN NO 3 TECHNICIAN NO 4 RETURN THIS TO INITIAL HERE 2000 Buell Distribution Corporation To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or serious injury 2 Disconnect negative battery cable 3 X1 Models Only Remove chin fairing See Section 2 of X1 Service Manual for procedure Discard wellnut 4 See Figure 1 Place a suitable jack under the swing arm mount block and raise until crankcase is supported by jack NOTE Steps 5 6 do not apply to M2 Cyclone models with original equipment shocks that were not equipped with a remote res ervoir 5 See Figure 2 Use a flex socket and extension to remove locknut and washer from front reservoir clamp Discard clamp and locknut Retain washer 6 See Figure 2 Loosen rear reservoir clamp Slide reser voir and mount block out of clamp Remove and discard clamp and mount block 7 Remove allen screw and locknut metric from front of shock and front shock mount Discard locknut 8 Remove allen screw washers and locknut metric from rear of shock and swingarm while supporting shock absorber Discard locknut Retain washers for re use 9 Remove and disc
8. ard shock absorber assembly 10 Remove two screws washers and voltage regulator from bracket 11 Remove small button head screw and metal locknut if present that secures voltage regulator bracket to front shock mount Leave bracket in place Discard screw and metal locknut NOTE Model Year 1999 motorcycles have unthreaded front shock mounts that require the use of washers and metal locknuts to secure the front shock mount to the crankcase Model Year 2000 front shock mounts were threaded and no locknuts were used The new front shock mount is not threaded and will require the use of the new mounting hardware which includes washers and metal locknuts 12 Remove top and bottom front shock mount bolts and washers and locknuts if present Remove and discard front shock mount Discard bolts locknuts and washers INSTALLATION IMPORTANT NOTE The new front shock mount MUST be used with the new shock absorber The new shock is 1 77 in 45 mm shorter than the previous shocks and requires the new front mount to align and install properly 1 See Figure 2 Install new front shock mount to crankcase with two new front shock mount bolts washers and metal locknuts Tighten bolts to 30 33 ft lbs 41 45 Nm NOTE Top bolt goes in from the left side bottom bolt goes in from right side The bottom bolt does not use washer under the bolt head 20f 5 b0887x2x Muffler Jack Figure 1 Jack Location on Mount Blo
9. ck Shock Removed for Clarity b0918x2x Nylon Reservoir Mount Block Locknut 2 Rear Reservoir Clamp Washers 2 Front Reservoir 2 Clamp Metal Locknut 2 30 33 ft lbs 41 45 Nm 40 45 ft lbs Included in Kit 54 2 61 Nm Figure 2 New Shock Absorber Assembly b0850x2 R Oil Feed Line Rear Reservoir Clamp Front Reservoir Clamp 1111111111111111C Chin Fairing Included in Kit Mount X1 Only Figure 3 Reservoir Clamps X1 Model Shown B 033A 2 Apply LOCITITE THREADLOCKER 243 Blue to threads of new button head fastener Attach voltage reg ulator bracket to front shock mount with small button head fastener Tighten fastener to 5 6 ft Ibs 7 8 Nm 3 Apply LOCTITE THREADLOCKER 243 Blue to threads of voltage regulator screws Install voltage regulator to bracket with two screws and washers Tighten fasteners to 9 11 ft Ibs 12 15 Nm NOTE All new shock absorbers including those on M2 Models have remote reservoirs that enable rebound damping adjustment 4 See Figure 2 Position new shock absorber from kit in mounting position 5 Loosely install bolt washers and new locknut through rear shock eye and swing arm 6 X1 Models Only Position new chin fairing bracket in mounting position on front shock eye 7 Loosely install bolt and new locknut through front shock eye and front shock mount and X1 chin fairing bracket if applicable
10. e set at 90 degrees to prevent torque multiplication by wrench Figure 7 Locknut Tightening Procedure 5 Using SHOCK PRELOAD ADJUSTING TOOLS Part No B 45110 hold adjusting nut in place with 60 mm ADJUSTING NUT WRENCH and tighten locknut to 65 72 ft lbs 88 98 Nm with 52 mm LOCKNUT CROW S FOOT set at 90 degrees to the torque wrench 6 Wipe excess grease off of shock absorber NOTE See Figures 5 and 6 To adjust rear shock to maximum damping setting use screwdriver to turn slotted dial on appropriate adjuster clockwise until it stops This is the maximum damping setting e See Figures 5 and 6 To adjust rear shock to factory rec ommended settings turn dial counterclockwise from maximum damping the amounts shown in Steps 7 and 8 to align the reference marks 7 See Figure 5 Set compression damping using the slot ted dial on the shaft at the rear of the shock New factory setting is as listed below e M2 X1 Models full damping minus 2 25 turns e 3 S3T Models full damping minus 2 5 turns 8 See Figure 6 Set rebound damping using the slotted dial on the remote reservoir at the front of the shock New factory setting is as listed below e M2 X1 Models full damping minus 1 5 turns e 3 S3T Models full damping minus 1 turn NOTE When preload is increased both compression and rebound damping should be increased If preload is decreased both compression and rebound damping should be decreased
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12. o charge transportation paid Buell Distribution Corporation reserves the right to conduct wave shipments in lieu of processing orders and or adjusting order quantities depending on the availability of parts The revised 0820 Recall Kit see below for correct Part Num ber consists of Customer Instructions for Shock Replacement and Adjustment Shock Absorber Clamp for shock reservoir to bracket Clamp for shock reservoir to oil return line Washer 1 4 in for reservoir clamp 2 Locknuts Nylon shock mounting Reservoir Mount Block Front Shock Mount 2 Front Shock Mount Bolts 2 Locknuts Metal for front shock mount 3 Washers for front shock mount New X1 Chin Fairing Bracket Wellnut Star Washer 3 8 in 1997 M2 S3 S3T only front shock mount not used Star Washer 1 4 in 1997 M2 S3 S8T only voltage regulator bracket not used e 2 Exhaust Port Gaskets not used e Screw for voltage regulator bracket New Header Tie bar Spacer not used The new shock recall kit is different depending on the motor cycle model See below for the correct recall kit part num bers X1 M2 Part No 94017Y 3 S3T Part No 94018Y REMOVAL All Models NOTE Perform the following procedures according to the guidelines given in the service manual for the model being serviced 1 Lift rear wheel off ground using REAR WHEEL SUP PORT STAND Part No B 41174 Secure front wheel of motorcycle in a suit
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