Isolators `96-`98
Contents
1. CAUTION Remove oil filter before raising frame Without removal oil filter will be damaged during procedure 5 11 12 13 14 15 16 17 18 19 20 Remove cap from oil tank Drain oil tank and remove oil filter Remove rear fender Remove rear brake caliper assembly Support caliper from frame with rope Label and detach feed vent and return hoses from oil tank Remove left rider footrest from footrest mounts Remove shift linkage taking care not to scratch primary cover Remove air cleaner cover and backplate This includes removing right side fairing lower on S2T S3T models Remove carburetor exhaust header and muffler Remove sprocket cover Unplug all wires which do not have adequate slack to support raising frame above engine These will include Neutral indicator wiring Cam position sensor connector Relay terminal on starter Oil pressure switch lead Voltage regulator wiring V O E S wiring Remove any restrictive cable straps from wiring harness and oil lines Note cable strap locations for reinstallation upon assembly All wires and hoses must have adequate slack when frame is raised and all oil and vent lines must not be pinched 2 QaO5 Place a crating strap between the engine cylinders and around the lift Tighten crating strap until snug Detach rear tie bar and chassis ground strap from frame Do not remove tie bars from engine See Figure 2 Re2. CEDURES REPAIR PROCEDURE Isolator Removal NOTE e Perform the following procedures according to the guide lines given in the service manual for the particular model and year being serviced Mark all hardware as it is removed so that it may be returned to it s original location b0420x3x Figure 1 Floor Hoist 1 Prepare motorcycle for isolator service a Remove saddlebags on S2T S3T models b Place vehicle on a lift and anchor front wheel in place c Raise rear wheel off lift using REAR WHEEL SUP PORT STAND Part No B 41174 To avoid accidental start up of vehicle and possible per sonal injury disconnect the battery cables before pro ceeding Always disconnect the negative cable first If the positive cable should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion producing personal injury 2 Disconnect both battery cables negative cable first 3 Remove seat fuel tank cover if applicable fuel tank and tail section 4 See Figure 1 Attach lifting straps to a floor hoist placed behind the lift Connect lifting straps to motorcycle frame tubes as shown SERVICE MANAGER SALES MANAGER PARTS MANAGER LEAD ROUTING TECHNICIAN TECHNICIAN NO 3 TECHNICIAN NO 4 TECHNICIAN NO 1 TECHNICIAN NO 2 RETURN THIS TO INITIAL HERE 1998 Buell Distribution Corporation
3. SERVICE BULLETIN Buell B 016 December 15 1998 AMERICAN MOTORCYCLES PRODUCT PROGRAM BP5 ISOLATOR KIT GENERAL The purpose of this service bulletin is to inform you that Buell Motorcycle Company has developed an Isolator Kit Part No 91360 99Y for motorcycles built prior to the 1999 model year This kit can be ordered to replace failed rear engine iso lators and to prevent future failures of the isolators VEHICLES INVOLVED All 1996 1998 Buell motorcycles could be subject to this condition DEALER ACTION The new rear Isolator Kit Part No 91360 99Y is available The kit includes two isolators and two shims Only install the new isolators with the raised letter B molded into the side Do not use the old isolator Part No 47680 94Y for replace ment purposes If a customer comes in with torn isolators on a pre 1999 model year motorcycle inspect isolators prior to disassembly to verify that the isolators are actually torn NOTE If an isolator s paint coating is cracked it may give the false impression that the isolator itself is damaged Inspect each isolator carefully and order an Isolator Kit Part No 91360 99Y only for vehicles with torn isolators In the interest of customer satisfaction if your customer expe riences a failure with the old style isolators the new isolators can be installed under warranty Vehicles beyond the warranty period will not require a prior authorization See CREDIT PRO
4. brake lamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper brake lamp operation could lead to personal injury 16 Turn ignition key switch to IGN Apply rear brake pedal to test brake lamp operation Turn ignition key switch to LOCK CREDIT PROCEDURES After servicing each vehicle file a warranty claim referencing Product Program BP5 in the Description of Repair or Com ments section of the claim Fill in the rest of the claim as follows Table 1 Product Program BP5 Claim Type BMC BGW Event 1 Qty amp Problem 0 47564 86 Part No Event 1 Additional 1 91360 99Y Replacement Qty amp Part No Part Description Rear Isolator Kit Primary Labor Code 2375 Time S2T S3T Models 3 1 Time All Other Models 2 8 Customer Concern Code 9203 Condition Code 2101 Use BMC if vehicle is still within factory warranty period use BGW if vehicle is beyond factory warranty period Vehicles beyond factory warranty period do not require prior authoriza tion for this product program NOTE If additional parts such as cable straps are required list them under Event 1 Additional Parts
5. his time apply LOCTITE THREADLOCKER 262 red Part No 94759 99 to isolator bolt threads 1 and LOCTITE ANTI SEIZE to bottom of isolator bolt head 2 Lower floor hoist and guide frame over swingarm mount block CAUTION Use caution when installing isolator bolts Bolts may be easily cross threaded Observe seam on rubber isolator after isolator bolt is tightened If seam twists apply more LOCTITE ANTI SEIZE to underside of isolator bolt heads Do not overtighten isolator bolts Too much torque may lead to premature isolator failure 3 As frame lowers install isolator bolts a Place washer 2 over isolator bolt Install assembly through isolators and into the swingarm mount block b Tighten to 100 110 ft lbs 135 6 149 1 Nm c See Figure 5 After tightening isolator bolts verify that seam on isolators is perpendicular to swingarm mount block If seam is not perpendicular loosen isolator hardware and realign 4 Install tie bars and chassis ground strap Tighten tie bar hardware to 30 33 ft lbs 40 7 44 7 Nm 5 Install carburetor air cleaner assembly and exhaust sys tem This includes installing right side fairing lower on S2T S3T models Reconnect all disconnected wires except battery cables Install shift linkage and left rider footrest Attach oil tank hoses and fill lubrication system Consult a service manual for oil type and amount 9 Install new cable straps around wiring and oil lines a
6. move isolators bolts 1 and washers 2 on each side Slowly raise floor hoist until rubber isolators 3 can be removed Frame will rise while engine and swingarm remain secured to lift by crating strap Remove rubber isolators Isolator Pin Inspection See Figure 3 After disassembly inspect frame mounted locating pins Pins must extend from frame between 0 080 0 120 in 2 032 3 048 mm If pin length is within limits continue with installation of new isolators and shims If pin length is greater than specification carefully file end of pin until it falls within specification File perpendic ular to pin end Pin must not have any sharp or uneven edges which could tear rubber isolator upon installation 2 of 4 b0702xsb Isolator bolt Washer Isolator Frame mounted locating pin BN Figure 2 Isolator Assembly Before Installing Kit Pin A gt K 0 080 0 120 in 2 032 3 048 mm Figure 3 Locating Pin Inspection Isolator Installation CAUTION Isolator bolts must be tightened within 30 minutes of applying LOCTITE THREADLOCKER Failure to tighten bolts within 30 minutes may cause LOCTITE to set 1 See Figure 4 Prepare isolator hardware for installation a Place isolator shim 5 next to swingarm mount block b Insert new rubber isolators 3 in place Align metal pin on frame 4 and hole in isolator c At t
7. s needed b0702xsb Isolator bolt Washer Isolator revision B Frame mounted locating pin Shim Se SNe Figure 4 Isolator Assembly After Installing Kit b0674x2x Isolator Seam ___ m Straight seam Twisted seam correct incorrect Figure 5 Isolator Alignment 3 of 4 WARNING Always test motorcycle brakes at low speed after servic ing or bleeding system To prevent personal injury Buell recommends that all brake repairs be performed by a Buell dealer or other qualified mechanic 10 Install rear brake caliper assembly 11 Install rear inner fender WARNING 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 and personal injury 12 Install tail section fuel tank fuel tank cover if applicable and seat WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion resulting in personal injury 13 Connect both battery cables positive cable first 14 Remove motorcycle from lift Install saddlebags on S2T S3T models 15 Check oil level after starting vehicle and allowing motorcy cle to reach operating temperature WARNING Check for proper
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