Tech Bulletin B-032 Exhaust Mount 95-00
Contents
1. SERVICE BULLETIN Buell B 032 AMERICAN MOTORCYCLES July 27 2000 PRODUCT PROGRAM BP7 EXHAUST HEADER MOUNT RETROFIT KIT GENERAL The purpose of this bulletin is to announce the release of a new kit for all 1995 2000 S1 S1W M2 S2 S2T S3 S3T and X1 Model Buell motorcycles and to provide installation instructions Buell Motorcycle Company has developed this kit as an upgrade to the exhaust header mounts currently in use The kits will be available on or before 31 July 2000 Kits must be ordered as required and purchase price will be reimbursed by warranty See CREDIT PROCEDURES The life expectancy of this product program is one year from the date of issue of this bulletin VEHICLES INVOLVED All domestic and HDI 1995 2000 S1 S1W M2 S2 S2T S3 S3T and X1 Model Buell motorcycles DEALER ACTION Follow the instructions provided to install the kit See below for list of Kit Contents Exhaust Header Mount Retrofit Kit Part No 1001 01A1 Description Quantity Support Header Assembly 1 Bracket Voltage Regulator not used 1 on S1 S1W models Washer 5 16 S1 S1W models only 1 Spacer Muffler Mount 1 Bracket Muffler Mount rear used on 1 1999 2000 Models Only Screw 5 16 18x1 1 2 Hex Head 2 Grade 8 Locknut metal 5 16 18 2 Cable Ties Thick 3 INSTALLATION The following procedure applies to all models unless other wise indicated Removing the Exhaust 1 Secure mo2. ains behind volt age regulator bracket c See Figure 1 Apply LOCTITE THREADLOCKER 243 Blue to threads of two original header support mount bolts Install voltage regulator bracket neader support assembly with two original header support mount bolts and washers and locknuts if present DO NOT tighten d Apply LOCTITE THREADLOCKER 243 Blue to threads of original small button head allen screw and install to voltage regulator bracket and shock mounting bracket DO NOT tighten e See Figure 4 Check voltage regulator bracket to verify that pin remains engaged in hole and that bracket does not pivot front to rear 10 S1 S1W Models Only See Figure 1 Install new washer provided in kit over hole at top of the header support mount between header support mount and crankcase Install header support mount with two original header support mount bolts and washers B 032 Header Support Mount Fasteners Bora al Button Hea Screw long e Button Head Allen Screw Large Washers 2 and Metal Locknut Figure 2 Original Exhaust Header Mount 1999 2000 b021r Flat Spot Under Mount Block Figure 3 Supporting Motorcycle with Jack Shock Absorber Removed for Clarity b0836x2 sc Voltage Regulator Mount Bracket C Pin Hole Header Support Mount Remove Paint From Shaded Area Figure 4 Voltage Regulator Bracket 3of5 11 See Figures 1 and 5 I
3. air sec tion Fill in the rest of the claim as follows Credit for Parts Claim Type BDS Quantity See Note Below 65300 94Y 65784 96Y 65784 96YA 65784 96YB 65930 99Y Problem Part Nos Part Description Header Support Mount 1995 2000 Models Rear Mount Bracket 1999 2000 Models Customer Concern Code 3201 Condition Code 3202 NOTE Quantity 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 Affected parts have been superseded Remove and destroy all affected parts from your inventory Order parts as required to restock your inventory 5 of 5
4. hers and metal locknut from header support mount Discard screw Retain washers and locknut for reuse NOTE Earlier models have unthreaded front shock mounting brack ets that used metal locknuts Later models have the threaded front shock mounting bracket and no locknuts b See Figure 2 Remove two header support mount bolts washers locknuts if present and header sup port mount allowing shock mounting bracket attached to front shock eye to hang free Discard header support mount Retain washers and two bolts 8 Inspect muffler inlet Oo sensor bung if present mounts and fasteners for cracks or damage Replace damaged parts as required See Credit Procedure NOTE The Lightning S1 and S1W do not use the provided voltage regulator bracket and instead use a washer between the header support mount and crankcase This washer is neces sary to maintain the correct alignment of the header support mount For Lightning S1 and S1W Models go to step 10 9 Install new voltage regulator bracket to new header sup port mount and install to crankcase muffler NOTE Scraping the paint from the voltage regulator bracket is required to ensure a good ground for the voltage regulator a See Figure 4 Scrape paint from inside corner of voltage regulator bracket on crankcase side b See Figure 4 Position new header support so pin engages hole in new voltage regulator bracket NOTE Make sure voltage regulator ground wire rem
5. nstall new grade 8 bolt original washer new spacer original washer and metal locknut to header support mount NOTE Spacer goes between front muffler mount tabs NOTE Step 12 only applies to 1999 and 2000 Models Earlier Mod els have a welded rear mount and will not use the provided rear mount Go to step 13 if servicing a pre 1999 motorcycle 12 1999 2000 Models Only See Figure 1 Remove and discard muffler mount from rear of muffler and install new muffler mount a Remove two screws lockwashers and washers from rear exhaust mount and Z bracket Discard screws and lockwashers Retain washers for reuse b Push rear of muffler down slightly and remove slide off and discard original rear muffler mount bracket c Slide new rear muffler mount bracket over muffler and install with two new grade 8 bolts provided in kit original washers and new metal locknuts NOTE Install two metal locknuts over weldnuts on right side d Tighten rear muffler mount bracket bolts to 22 24 ft lbs 30 33 Nm e Tighten rear muffler mount bracket metal locknuts to 20 22 ft lbs 27 30 Nm 13 Tighten header support mount fasteners a Tighten two header support mount bolts to 30 33 ft Ibs 41 45 Nm b Tighten button head allen screw to 9 11 ft lbs 12 15 Nm c Tighten front muffler mount bolt to 22 24 ft lbs 30 33 Nm 14 Lower and remove bottle jack from motorcycle NOTE For Lightning S1 and White Lightning S1W m
6. odels proceed to step 16 15 See Figure 6 Install voltage regulator a Install voltage regulator to new bracket with original socket head screws and washers Tighten screws to 9 11 ft lbs 12 15 Nm b See Figure 7 Route voltage regulator wire harness between shock mounting bracket and oil line c See Figure 8 Mate connector 17 halves and secure with cable tie d See Figure 6 Connect ground wire bullet connector to main wire harness e See Figure 8 Push connector 17 behind gearcase cover and secure connector 17 to oil pump fitting with cable tie f See Figure 8 Secure voltage regulator wire harness to oil line and oil pressure switch harness with cable tie 16 Reconnect battery negative cable to negative terminal Tighten terminal to specification given in service manual for model being serviced 40f 5 I b0837x2x Included in Kit I Header Support amp Mount Bolt reused Header Support Mount ra Voltage Regulator Mount Bracket _ Bolt Grade 8 Ca Va Spacer a Figure 5 Header Support Mount all except S1 S1W Washer N b0838x7x Voltage Regulator pe Bracket O Washers 2 Screws 2 N A Sg M 2 y I a a ka pE Ground lk Wire Bullet Lia Connector Header Voltage Support Mount Regulator Connector 17 included in Kit Figure 6 Voltage Regulator Revi
7. rough screw hole and remove short button head allen head screw washer and metal locknut Remove voltage regulator mounting bracket from header support mount Retain fasteners for reuse ROUTING SERVICE SALES PARTS LEAD TECHNICIAN TECHNICIAN TECHNICIAN TECHNICIAN RETURN MANAGER MANAGER MANAGER TECHNICIAN NO 1 NO 2 NO 3 NO 4 THIS TO INITIAL HERE 2000 Buell Distribution Corporation b0835x2x Rear Muffler Mount Bracket Metal Locknuts 2 20 22 ft lbs 27 30 Nm Socket Head Screws 2 9 11 ft lbs Te 12 15 Nm Ground Wire Bullet Connector Figure 1 Modified Exhaust Mounting System 1999 2000 Models 2of5 Z Bracket on all except 1996 98 S1 S1W S3 S3T and M2 Models Header Support Mount Washer Bolts S1 S1W Models Only 2 30 33 ft lbs a 41 45 Nm Header Support Mount D I Bolts 2 22 24 ft lbs 30 33 Nm Washer 2 Grade 8 Bolt 22 24 ft lbs 30 33 Nm Muffler all similar except 1995 96 S2 S2T ow Metal Locknut Voltage Regulator ounting Bracket all except S 1 S1W Washers 2 Voltage Regulator ve Connector 17 Included in Kit B 032 6 See Figure 3 Position bottle jack under swing arm mount block and raise motorcycle just enough to unload rear suspension rear wheel remains on lift 7 Remove and discard header support mount from muffler and crankcase a See Figure 2 Remove large button head allen screw two was
8. sed Mounting b0840x7x Voltage Regulator Wire Harness Oil Pressure Switch Harness l Figure 7 Voltage Regulator Wire Harness Routing B 032 b0841x7x Connector 17 Cable Tie a Cable Tie Included in Kit Figure 8 Cable Tie Locations CREDIT PROCEDURE VEHICLE REPAIR After servicing each vehicle file a warranty claim referencing Service Bulletin B 032 in the Description of Repair or Com ments section of the claim Fill in the rest of the claim as follows Credit for Labor Claim Type BP7 Event 1 Qty amp Problem Part No 0 65784 96YB Event 1 Additional Replacement Qty amp Part No 1 S1001 01A1 Exhaust Header Mount Retrofit Kit Part Description Primary Labor Code 2660 Time 1 0 hr All Models Customer Concern Code 3201 Condition Code 3202 NOTE f additional parts such as cable straps are required list them under Event 1 Additional Parts e List any major components inspected in Step 8 found to be defective and replaced under Event 1 Additional Parts e Use of incorrect claim type will cause claim to be sus pended and or be rejected and credit delayed B 032 CREDIT PROCEDURES DEALER STOCK PARTS Remove and destroy all affected parts from your inven tory To receive credit complete a regular warranty claim referenc ing Service Bulletin B 032 in the Description of Rep
9. torcycle on a suitable lift 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 NOTE The S1W and S1 negative battery cables were recalled under safety recall 0811 If this recall service was not performed refer to Service Bulletin B O19INT and perform recall proce dure before continuing 2 Disconnect negative battery cable from battery terminal NOTE Lightning S1 and White Lightning S1W models have side mounted voltage regulators and will not need to perform steps 3 through 5 For S1 and S1W models go to step 6 3 Remove voltage regulator from bracket a See Figure 1 Remove two socket head screws and voltage regulator from bracket Leave ground wire connected to back of voltage regulator b Cut cable ties which secure voltage regulator wire harness to oil pump fitting Pull voltage regulator connector 17 down from under gearcase cover c Cut cable tie that secures connector halves together and disconnect connector 17 d Remove ground wire and disconnect connector 17 halves e Set aside any star washers that may be present behind voltage regulator and or bracket for reuse 4 See Figures 1 and 2 Remove long button head screw washer and metal locknut from voltage regulator mount ing bracket Discard long button head screw 5 Insert ball end allen wrench th
Download Pdf Manuals
Related Search