Buell S3T Thunderbolt Service Manual (2002)

Buell S3T Thunderbolt Service Manual (2002)
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Factory service manual part number 99489-02Y for the 2002 Buell S3T Thunderbolt. This 450-page English PDF is searchable and printable and covers the complete motorcycle, including scheduled maintenance, chassis, 1,203 cc engine, Dynamic Digital Fuel Injection diagnostics, electric starter, five-speed drive/transmission, electrical systems, wiring information, tools, connectors and metric conversions.

About the Manual

Manual type
Factory Service Manual
Years covered*
2002
Pages
450
Language
English
Format
PDF
Main sections
91
Searchable PDF
Yes
Printable PDF
Yes
File size
12.6 MB
Delivery
Digital download

* Indicative only. Please do your own research and confirm compatibility with your exact motorcycle and model year before purchasing.

Buell Thunderbolt S3T 2002 DDFI tube-frame sport-touring specification Motorcycle Details

Manufacturer
Buell
Series
Thunderbolt
Models Covered
S3T
Generation / variant
2002 DDFI tube-frame sport-touring specification
Engine
Air-cooled, four-stroke, 45-degree V-twin, 2 cylinders
Displacement
1,203 cc (73.4 cu in)
Bore × Stroke
88.849 x 96.838 mm (3.498 x 3.8125 in)
Compression Ratio
10.0:1
Cooling System
Air-cooled
Fuel System
Buell Dynamic Digital Fuel Injection (DDFI), open/closed-loop electronic engine management with oxygen-sensor feedback and returnless fuel system
Clutch
Wet multi-disc clutch; 8 friction plates and 6 steel plates
Transmission
5-speed, foot shift
Final Drive
Toothed belt final drive; 27-tooth transmission sprocket, 61-tooth rear sprocket, 128-tooth belt; 2.10:1 ratio
Maximum power
101 hp @ 6,200 rpm
Maximum torque
90 ft-lb @ 5,500 rpm
Ignition
Sequential, non-waste spark
Idle speed
850-1,050 rpm
Wheelbase
55 in (1,397 mm)
Seat height
31.0 in (787 mm)
Ground clearance
5.2 in (132.1 mm)
Rake
24.5 degrees
Trail
3.8 in (96.5 mm)
Front wheel travel
4.7 in (119.4 mm)
Rear wheel travel
4.6 in (116.8 mm)
Wet weight
518 lb (235 kg)
GVWR
915 lb (415 kg)
Front tire
120/70 ZR17 Dunlop Sportmax II Touring Radial D205F
Rear tire
170/60 ZR17 Dunlop Sportmax II Touring Radial D205
Front fork oil
Type E, 15.36 oz (450 cc) per fork
Battery
12 VDC, 18 Ah sealed
Charging system
22 A @ 3,600 rpm; regulator output 13.8-15 VDC

What’s Included in the Buell Thunderbolt S3T 2002 DDFI tube-frame sport-touring specification Service Manual?

  1. Maintenance - General and Fluid Requirements
  2. Battery
  3. Engine Lubrication System
  4. Brakes
  5. Shift Linkage Rod Adjustment
  6. Brake Pads and Rotors
  7. Tires and Wheels
  8. Clutch
  9. Drive Belt Deflection
  10. Drive Belt and Sprocket
  11. Primary Chain
  12. Preload Adjustment
  13. Suspension Damping Adjustments
  14. Front Fork
  15. Steering Head Bearings
  16. Spark Plugs
  17. Air Cleaner
  18. Ignition Timing
  19. Handlebars and Throttle Cables
  20. Headlamp
  21. Storage and Troubleshooting
  22. Chassis Specifications and Tire Specifications
  23. Vehicle Identification Number
  24. Wheels, Front Wheel and Rear Wheel
  25. Cast Rim Runout and Tires
  26. Front and Rear Brake Systems
  27. Front Fork and Fork Stem/Bracket Assembly
  28. Steering Head Lock
  29. Swingarm, Rear Isolators and Rear Shock Absorber
  30. Suspension Theory and Adjustments
  31. Throttle and Clutch Controls
  32. Handlebars and Exhaust System
  33. Footrests, Sprocket Cover and Stone Guard
  34. Front Fender, Rear Fender and Tail Section
  35. Front Fairing and Seat
  36. Side Stand, Saddlebags and Fairing Lowers
  37. Engine Specifications
  38. Engine
  39. Stripping Motorcycle for Engine Repair
  40. Installing the Engine
  41. Cylinder Head
  42. Cylinder and Piston
  43. Lubrication System and Oil Hose Routing
  44. Oil Tank and Oil Pressure Indicator Switch
  45. Crankcase Breathing System
  46. Oiling System
  47. Oil Pump and Oil Filter Mount
  48. Hydraulic Lifters
  49. Gearcase Cover and Cam Gears
  50. Crankcase
  51. Fuel System Specifications
  52. Dynamic Digital Fuel Injection
  53. Diagnostic Introduction and Trouble Codes
  54. Scanalyzer and Breakout Box Diagnostics
  55. Fuel Pressure and Idle Speed Control
  56. Electronic Control Module
  57. Cam Position and Oxygen Sensors
  58. Engine Temperature, Bank Angle and Intake Air Temperature Sensors
  59. Throttle Position Sensor
  60. Fuel Tank, Vent Valve, Inline Fuel Filter and Fuel Pump
  61. Throttle Body and Intake Manifold
  62. Air Cleaner and Evaporative Emissions Control
  63. Electric Starter Specifications
  64. Electric Starter System and Starting System Diagnosis
  65. Starter Activation Circuits and Diagnostics
  66. Starter System Testing
  67. Starter and Starter Solenoid
  68. Drive/Transmission Specifications
  69. Primary Chain and Drive Belt
  70. Clutch Release Mechanism
  71. Primary Drive/Clutch
  72. Transmission and Transmission Case
  73. Shifter Forks and Drum
  74. Mainshaft and Countershaft
  75. Main Drive Gear
  76. Access Door and Right Transmission Case Bearings
  77. Transmission Installation and Shifter Pawl Adjustment
  78. Electrical Specifications
  79. Ignition System, Key Switch, Ignition Coil and Spark Plug Cables
  80. Starter Interlock and Diodes
  81. Charging System, Alternator and Voltage Regulator
  82. Battery
  83. Headlamp, Tail Lamp and Turn Signals
  84. Handlebar Switches and Horn
  85. Neutral Indicator, Fuses, Circuit Breakers and Relay Block
  86. Speedometer, Speed Sensor and Performance Check
  87. Tachometer, Performance Check and Clock
  88. Wiring Diagrams
  89. Appendix A - Tools
  90. Appendix B - Electrical Connectors
  91. Appendix C - Metric Conversions and Torque Master Values

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About the Buell S3T

The Thunderbolt sport-touring line emerged during a major expansion of Buell's road-bike range. In its 1996 model preview, Cycle World reported that the S3 Thunderbolt and its S3T touring derivative were due to reach dealers in late 1996 or early 1997. The following year, the magazine described the new S3 as sharing little beyond name and family resemblance with the earlier S2, positioning the redesigned Thunderbolt as a compact, quick-steering machine with enough comfort and range for serious road use.

The S3T developed that concept into a more dedicated sport-touring V-twin motorcycle. It retained Buell's short-wheelbase, centrally massed chassis philosophy and Sportster-derived 45-degree V-twin, while adding the touring equipment reflected throughout the factory literature: a larger fairing, fairing lowers and hard saddlebags. The result combined American V-twin torque with 17-inch radial tires, adjustable suspension and a 55-inch wheelbase, giving the Thunderbolt a distinctive alternative to the multi-cylinder sport-tourers of the period.

A major technical evolution arrived around the 1999 model year. Contemporary testing documented the change from carburetion to Buell Dynamic Digital Fuel Injection, together with a redesigned frame, revised engine mounting, a cast-aluminum swingarm and broader suspension adjustment. Buell's later factory service material confirms DDFI components for 1999-and-later S3/S3T applications. This moved the later Thunderbolt family into closed-loop electronic fuel control while retaining the air-cooled 1,203 cc pushrod V-twin and belt final drive that gave the model its characteristic mechanical identity.

For 2002, the factory specification had matured into a 1,203 cc, 10.0:1-compression package rated at 101 hp at 6,200 rpm and 90 ft-lb at 5,500 rpm, driving through a five-speed transmission and toothed belt final drive. The 2002 chassis specification lists a 24.5-degree rake, 3.8-inch trail, 4.7 inches of front-wheel travel and 4.6 inches at the rear, with wet weight at 518 lb. Harley-Davidson's official 2002 S3T Thunderbolt parts catalog identifies the FS model code specifically as Thunderbolt S3T and model-year code 2 as 2002. By the following model year, Buell service literature was centered on the XB9R Firebolt and XB9S Lightning, placing the 2002 S3T at the close of the company's classic tube-frame Thunderbolt period.

This factory service manual applies specifically to the 2002 S3T Thunderbolt and covers the complete motorcycle across maintenance, chassis, engine, DDFI fuel system, starter, drive/transmission and electrical sections. Related Thunderbolt material is available in the Buell S3T catalog.

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