Complete PDF version of the Service Manual for the Buell S3T Thunderbolt. A MUST for every S3T owner.
Download: Immediately after payment!
OEM Original factory workshop manual.
Models covered by this manual: 2002
Number of pages: 450 pages
Table of contents:
This PDF repair manual can be downloaded right after the payment process in complete, on the device of your choice.
We do not offer printed manuals, for the following reasons:
- it is more eco-friendly to use a digital version
- your manual never gets dirty or greasy
- you can always choose to print the specific page(s) you need to work on your bike
- you receive your manual immediately after payment
- it is searchable
Buell S3/S3T Thunderbolt
Buell Motorcycles, headquartered in Grand Rapids, Michigan, was created in 1983 by ex-Harley-Davidson engineer Erik Buell. Harley-Davidson purchased a 49 percent stake in Buell in 1993, and by 2003, Buell had become a completely owned subsidiary of Harley-Davidson. Buell stated on November 17, 2006, that it has built and shipped its 100,000th motorbike.
Harley-Davidson announced the termination of the Buell product line on October 15, 2009, as part of its plan to focus on the Harley-Davidson brand. The final Buell motorcycle built by Harley-Davidson occurred on October 30, 2009, bringing the total number produced to 136,923.
Erik Buell announced the launch of Erik Buell Racing in November 2009, an independent company run by Erik Buell that initially produced race-only versions of the 1125R model, then offered an updated 1190RS model for the street or the track, and produced further improved 1190RX and 1190SX models for street or track use.
Buell Motorcycles announced in February 2021 that they will resume manufacture under the new ownership of Erik Buell Racing (EBR). Buell indicated that they will employ the superbike platforms built between 2011 and 2020 to expand their model line to about ten models by 2024. Touring, dirt, adventure, and cruiser versions will be available.
The S3 Thunderbolt sport-touring vehicle was manufactured from 1997 to 2003, along with a mechanically identical S3T “Touring” type that was available until model year 2000. The 1,203 cc air-cooled V-Twin engine was housed in a tubular frame as a stressed member. The engine produced 91 horsepower (68 kW) in 1997 and increased to 101 hp (75 kW) in subsequent years due to improved cam profiles and redesigned Thunderstorm cylinder heads. While the bike’s general appearance remained consistent throughout the model run, major improvements were made in 1999 that distinguished it and later versions from the 1997 and 1998 motorcycles.
The early motorcycles were outfitted with a rectangular section steel rear swingarm, WP Suspension front forks and rear shock, a Keihin 40 mm CV carburetor, and a Performance Machine six-piston front brake caliper. Beginning in 1999, a new cast aluminum rear swingarm, as well as Showa front suspension forks and rear shock, were used. Nissin now manufactured the front brake caliper, which was still a six-piston unit. The most significant technological advancement was the new Dynamic Digital Fuel Injection (DDFI) system, which replaced the previous carburetor.
The S3 had a half fairing that around the headlamp and provided adequate wind protection for the rider’s body. The S3T model then received lower fairing extensions, which improved wind protection for the rider’s legs. The S3T also came with hard saddlebags that could be color-matched to the bike and came in “wide” for optimum capacity or “narrow” for a lighter feel. Aside from the lower fairings and saddlebags, the S3T had a longer handlebar for a more upright, comfortable riding stance. Each of the components that distinguished the S3T were available as extras for the original S3 model.