Front Isolator Mount System
Contents
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3. on TALON and hd net com IMPORTANT NOTE Because only registered owners as shown on the attached list will receive notification from Buell Distribu tion Corporation we request that you contact any own ers of vehicles still 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 pro vide 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 Initial shipment of recall kits will begin on or before May 30 1999 All kits will be shipped direct from the Franklin Distribu tion Center no charge transportation paid To order the remainder of kits that may be needed please fill out the attached order form and send fax it to the Warranty Depart ment at FAX 414 343 8346 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 domestic US Canada Japan and New Zealand front isolator mount system recall kit Part No 93916Y consists of Front Isolator Mount 2 Front Isolator Mount Bolts 2 Front Isolator Mount Thick Washers Isolator Locknut Cable Tie for fuel tank vent hose Hose Clamp for fuel tank hose to fuel supply valve INSTALLATION NOTE Perform the following pr
4. SERVICE BULLETIN Buell B 018 May 13 1999 AMERICAN MOTORCYCLES SAFETY RECALL CODE 0810 FRONT ISOLATOR MOUNT SYSTEM GENERAL Buell Motorcycle Company has learned that certain 1997 and 1998 Buell motorcycles were built with an isolator mount sys tem that could lose clamp load Should this condition occur it may allow the engine to move unexpectedly in the frame and cause an unintended distraction to the operator which could result in an accident Accordingly Buell Motorcycle Company is conducting a voluntary recall campaign to formally recall all potentially affected motorcycles This campaign involves all 1997 and 1998 S1 Lightning S1 White Lightning M2 Cyclone 53 Thunderbolt and S3T Thun derbolt model Buell motorcycles manufactured between Jan uary 6 1996 and June 16 1998 This condition will be remedied by replacing the front isolator mount system on all potentially affected vehicles DEALER ACTION AFFECTED VEHICLES Buell Distribution Corporation has attached 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
5. artup If the positive cable should contact ground with the nega tive cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 2 Disconnect negative battery cable 3 Position floor jack under engine under front shock mount to support engine 4 From left side of motorcycle remove and discard isolator locknut and remove bolt two washers and D washer Remove air cleaner cover and filter box Remove two nuts and 2 socket head screws from air cleaner backplate and front isolator mount 7 Remove and discard two bolts and washers from left and right side of front isolator mount 8 Remove front isolator mount from left side of motorcycle B 018 Always wear proper eye protection and gloves when working with compressed air Debris or solvent may be blown out with enough force to penetrate skin or cause eye injury Failure to comply could result in death or seri ous injury 9 Clean residual loctite from threads in engine with suit able nonflammable solvent and dry with compressed air 10 Apply LOCTITE THREADLOCKER 271 red to threads of new front isolator mount bolts 11 Apply a thin film of clean HD 20W50 engine oil to both sides of new thick washers and to bottom of bolt heads Exercise caution to avoid mixing oil on washers with loc tite on bolts 12 Position new front isolator mount and secure with two new front bolts with new thick washers Tighten bol
6. emove and discard two bolts and washers from left and right side of front isolator mount 9 Remove front isolator mount from left side of motorcycle b0041b Locknut D Washer ae Isolator SY Washer Front Isolator 9 pee Mount Washer Isolator Washer 2 Front Isolator Bolt 2 Included in Kit Figure 1 Front Isolator Mount Always wear proper eye protection and gloves when working with compressed air Debris or solvent may be blown out with enough force to penetrate skin or cause eye injury Failure to comply could result in death or seri ous injury 10 Clean residual loctite from threads in engine with a suit able nonflammable solvent and dry with compressed air 11 Apply LOCTITE THREADLOCKER 271 red to threads of new front isolator mount bolts 12 Apply a thin film of clean HD 20W50 engine oil to both sides of new thick washers and to bottom of bolt heads Exercise caution to avoid mixing oil on washers with loc tite on bolts 13 Position new front isolator mount and secure with two new front bolts with new thick washers Tighten bolts to 60 ft los 81 Nm initially and then loosen each bolt one full turn Tighten bolts again to 60 ft lbs 81 Nm NOTE Make sure flat on D washer remains oriented to front of motorcycle while tightening bolt 2013 14 Position washer between front isolator mount and isola tor Install bolt washer D washer and ne
7. move all affected front isolator mounts Part Nos 16271 97Y and 16298 97Y from your inventory To receive credit complete a regular warranty claim referencing Service Bulle tin B 018 in the Description of Repair section Fill in the rest of the claim as follows Table 1 Credit for Parts Claim Type BDS Quantity See Note Below Event 1 Problem Part No 16271 97Y Domestic Event 2 Problem Part No 16298 97Y International Part Description Isolator Mount Customer Concern Code 9205 Condition Code 9111 NOTE Quantity and Problem Part may vary depending upon what you have in stock If you happen to have both isolator mounts in stock list two separate events on the claim as demon strated above Upon receipt of properly completed claim for parts in dealer stock you will receive the appropriate credit for parts DESTROY AND DISCARD ALL AFFECTED PARTS FROM YOUR STOCK Buell Distribution Corporation will advise at a later date how to order updated isolator mounts to replenish your stock DO NOT ORDER THE RECALL KITS TO RESTOCK YOUR INVENTORY 3 of 3 VSNNI Ov0l s 12391 UO Ajdde yey sexe e90 Jo JUaWAed 104 aes JO 5501 40 se aw S Jo 10 UA O18Z SNjd
8. ocedures according to the guide lines given in the service manual for the model being ser viced fuel tank must be removed from 53 and S1W models to perform this service The fuel tank does not need to be removed from S1 and M2 models S3 S3T S1W Models 1 Position motorcycle on a suitable lift and position REAR WHEEL SUPPORT STAND Part No B41174 under the swing arm Secure motorcycle to lift Always disconnect the negative battery cable when working on motorcycle to prevent accidental startup If the positive cable should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion which could result in death or serious injury 2 Disconnect negative battery cable 3 Remove seat and fuel tank See appropriate service manual Section 4 for procedure 4 Remove airbox cover and left fairing lower on S3Ts and filter box 5 Remove two nuts and 2 socket head screws from air cleaner backplate and front isolator mount 6 Position floor jack under engine under front shock mount to support engine 7 Remove and discard isolator locknut and remove bolt two washers and D washer PARTS MANAGER LEAD TECHNICIAN SERVICE MANAGER SALES ROUTING MANAGER TECHNICIAN NO 1 TECHNICIAN NO 2 TECHNICIAN NO 3 TECHNICIAN NO 4 RETURN THIS TO INITIAL HERE 1999 Buell Distribution Corporation 8 R
9. ts to 60 ft lbs 81 Nm initially and then loosen each bolt one full turn Tighten bolts again to 60 ft lbs 81 Nm NOTE Make sure flat on D washer remains oriented to front of motorcycle while tightening bolt A needle nosed pliers can be used to position the locknut over the bolt 13 Position washer between front isolator mount and isola tor Install bolt washer D washer and new locknut 14 Making sure flats on D washer stay oriented to front of bike tighten bolt to 100 ft lbs 135 6 Nm 15 Apply LOCTITE THREADLOCKER 243 blue to threads of two air cleaner backplate screws Install two screws to air cleaner backplate and front isolator mount Install locknuts to screws 16 Install air cleaner filter box and cover 17 Connect negative battery cable B 018 CREDIT PROCEDURES VEHICLE REPAIR For each vehicle serviced place a C in the letter box on the Buell Dealer Service Card Destroy and discard the original isolator mount and hardware Send the properly completed dealer service cards to Buell Distribution Corporation Upon receipt and processing of your properly completed dealer ser vice cards you will be credited for 1 4 hours for M2 S1 S1W 53 models and 1 6 hours for 537 models Both times include 0 1 hour administrative time and your cost for loctite No credit will be issued for the kits as they were sent no charge transportation paid CREDIT PROCEDURES DEALER STOCK PARTS Re
10. w locknut 15 Making sure flat on D washer stays oriented to front of bike tighten bolt to 100 ft lbs 135 6 Nm 16 Apply LOCTITE THREADLOCKER 243 blue to threads of airbox screws Install airbox screws to airbox and front isolator mount Install locknuts to screws 17 Install air cleaner filter box and cover 18 Connect negative battery cable 19 Install fuel tank and seat On motorcycles with original fuel tank mounting hardware tighten fuel tank hardware to specification listed below 9 11 ft lbs 12 2 14 9 Nm On motorcycles that have had the fuel tank retention recall service performed make sure plates are oriented properly and tighten fuel tank hardware to specification listed below 18 23 ft lbs 24 4 31 2 Nm then wait 3 5 minutes and tighten again to 18 23 ft lbs 24 4 31 2 After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control These events could result in death or serious injury NOTE A new cable tie and new hose clamp have been provided in the kit to install the fuel tank vent hose and supply hose 51 2 Models 1 Position motorcycle on a suitable lift and position REAR WHEEL SUPPORT STAND Part No B41174 under the swing arm Secure motorcycle to lift Always disconnect the negative battery cable when working on motorcycle to prevent accidental st
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