This action might not be possible to undo. Are you sure you want to continue?
CHECKING AND ADDING OIL
Check engine oil level in oil reservoir at least once every 500 miles (800 km). Check level more frequently if engine uses more oil than normal or if vehicle is operated under harsh conditions. Check oil when engine is warmed up to operating temperature (see Hot Check).
Normal fuel combustion in a gasoline engine produces water vapor and carbon dioxide along with other gases and particulates. When ﬁrst starting and warming an engine, some of the water vapor that gets into the engine crankcase condenses to form liquid water. If the engine is driven long enough to thoroughly warm the crankcase, most of this liquid water is again vaporized and exhausted through the crankcase breather system. A moderately driven vehicle making short runs may not be able to vacate water vapors allowing liquid water to accumulate in the oil reservoir. This is especially true if the vehicle is operated in cold weather. In freezing weather, an accumulation of water in the engine oil may become slush or ice, which can block oil lines and lead to severe engine damage. Water remaining in the engine oil for long periods of time can form an acidic sludge that is corrosive to metal engine parts and causes accelerated wear of moving components. In winter the oil change interval should be shorter than normal. The colder the weather, the shorter the recommended oil change interval. A vehicle used only for short runs in cold weather must have the engine oil drained frequently.
CHANGING OIL AND FILTER
After a new engine has run its ﬁrst 1000 miles (1600 km) and at 5000 mile (8000 km) intervals or annually thereafter, completely drain oil reservoir of used oil. If riding habits include severe dust conditions, operation at temperature above 80 ° F, extensive idling, speeds in excess of 65 m.p.h. and /or extensive two up riding or similar loads the oil should be changed at 2,500 mile (4000 km) intervals. Reﬁll with fresh oil. Always change oil ﬁlter when changing engine oil. NOTE See 1.5 ENGINE LUBRICATION SYSTEM for more information on checking oil level and changing oil and ﬁlter.
2002 Buell P3: Engine
OIL HOSE ROUTING
See Figure 3-83. Engine oil runs through the frame backbone which serves as the oil reservoir. From the bottom of the reservoir, the vent hose and the return hose run downward below the battery tray. A rubberized clamp secure the hoses in place. See Figure 3-83. A T-ﬁtting on the bottom left side of the oil reservoir, supplies the feed hose and the oil drain hose. See Figure 3-84. The drain hose attaches to the left side of the footpeg support bracket frame. See Figure 3-85. The feed and return hoses run together alongside the engine and forward to the oil pump. The feed hose attaches to the rear most oil pump ﬁtting; the return hose connects forward and above. See Figure 3-86. After diverging from the feed and return hoses, the vent hose continues on to the right side of the motorcycle. Here the vent hose connects to an elbow ﬁtting on the gearcase cover.
1. 2. Breather Hose Drain Hose Figure 3-84. Drain Hose
1. 2. 3. 4. 5.
1. 2. 3.
Feed Hose Oil Pump Steel line connection Figure 3-85. Oil Pump Connections
Feed Hose Drain Hose Vent Hose Return Hose T-ﬁtting Figure 3-83. Oil Reservoir Hose Assembly
1. 2. 3. 4.
Vent Hose Clamp Elbow Fitting Gearcase Cover Figure 3-86. Vent Hose Connection
2002 Buell P3: Engine
See Figure 3-87. Engine oil is stored in the frame backbone which acts as an oil reservoir. From the bottom of the reservoir, the vent hose and the return hose run downward below the battery tray. A rubberized clamp secure the hoses in place.
1. 2. 3. 4. 5. 6. 7. 8.
3/8 inch Clamp Feed Hose Drain Hose 1/4 inch Clamp Vent Hose Return Hose T-ﬁtting Dipstick
Figure 3-87. Oil Reservoir (Frame Backbone)
2002 Buell P3: Engine
Grounded oil switch wire. Engine is idling below 1000 RPM. NOTE If the ignition is turned back on immediately after the engine is stopped. Dead battery (see NOTE).14 OIL FILTER MOUNT).. oil pressure will vary from 6-8 psi (42-55 KPa). oil pressure will vary from 10-12 psi (69-83 KPa). Oil Pressure Indicator Switch Ignition switch is turned on prior to starting engine.10 OIL PRESSURE SIGNAL LIGHT The oil pressure signal light turns ON when: ● ● ● ● Oil Pressure Indicator Switch Figure 3-88. resulting in higher oil pressure. ● ● ● ● ● ● ● ● Table 3-11. use OIL PRESSURE GAUGE (Part No. Clogged feed line (ice and sludge. HD-96921-52B) and OIL PRESSURE GAUGE ADAPTER (Part No. thereby completing the signal light circuit and causing the indicator lamp to illuminate. At 2500 RPM. the volume of oil circulated through the oiling system increases. the volume of oil pumped is also reduced. Malfunctioning or improperly installed check valve (see 3. OIL PRESSURE SIGNAL LIGHT Stays on at speeds above idle. Remove oil pressure indicator switch and insert pressure gauge ﬁtting. When an engine is cold. freezing temperatures). Burned-out signal bulb. When an engine is operated at high speeds. To check oil pressure. Troubleshooting Oil Pressure Signal Light PROBABLE CAUSES The oil pressure signal light turns OFF when: ● Oil is circulating with adequate pressure through the engine running at 1000 RPM or greater. Does not glow when ignition is turned on (prior to operating engine). Empty oil reservoir. As engine speed is reduced. ● ● ● ● 3-46 2002 Buell P3: Engine . The oil pump is non regulatory and delivers its entire volume of oil under pressure to the oil ﬁlter mount. thicker). Malfunctioning signal switch. spring tension holds the switch contacts closed. HD-96940-58).14 OIL FILTER MOUNT). 7639 3. Oil pressure is abnormally low in the running engine. Ride motorcycle at least 20 miles (32 km) at or above 50 MPH (80 KM/H) until engine oil reaches normal operating temperature.HOME OIL PRESSURE INDICATOR SWITCH GENERAL The oil pressure indicator switch is a pressure-actuated diaphragm-type switch. Flickers at idle. When oil is not circulating through the system or when oil pressure is low. resulting in lower oil pressure. Malfunction in wiring. Malfunctioning signal switch. the oil light may not turn on right away because of oil pressure retained in the ﬁlter housing. Incorrect idle speed. Troubleshooting information is listed in Table 3-11. Oil is not circulating through the running engine. Air-bound oil line.e. the engine oil will be more viscous (i. Malfunctioning check valve (see 3. Diluted oil. At idle speed (950-1050 RPM). OIL PRESSURE See Figure 3-88.
The crankcase air passes through the breather assembly to the positive crankcase vent valve (PCV) located on top of the rocker box cover. Positive Crankcase Vent Valve (PCV) Crankcase Breather Hose Carburetor Venturi Figure 3-89.11 2 1 2 3 1. 2. 3. a mixture of crankcase air and oil mist is vented up the push rod covers to the upper rocker box.HOME CRANKCASE BREATHING SYSTEM GENERAL See Figure 3-89. Crankcase Breathing System. Any residual oil drains to the crankcase breather drain hose located behind the right footrest support (located by the oil tank drain hose). From the PCV the air enters the crankcase breather hose. 2002 Buell P3: Engine 3-47 . The oil mist collects and eventually returns to the crankcase through oil passageways in the cylinder head. The crankcase breather hose splits with one hose (crankcase breather hose) going to the air cleaner and the other hose (crankcase breather drain hose) going to the footrest support bracket. 7677 3. On piston downstroke. The crankcase breather drain hose should be drained at each oil change. Air is allowed to escape the rocker box by exiting the positive crankcase vent valve located on top of the rocker box. Crankcase air is routed to the air cleaner box where it is directed into the carburetor’s venturi.
5. Oil ﬂowing from the ﬁlter adapter opens the check ball. Adequate oil pressure in the ﬁlter mount cavity activates the oil pressure signal light switch and shuts off the oil pressure signal light. Oil enters the feed section and ﬁlls a cavity located under the feed pump. The check ball opens at 4-6 psi (28-41 kPa) oil pressure. Oil collected in the sump is splash-fed to the pistons. 11. and ﬂows into the ﬁlter adapter (ﬁtting which connects ﬁlter to ﬁlter mount). 3. Oil enters the peripheral cavity of the oil ﬁlter. oil ﬂows into the crankcase feed galley. With the check ball open. 18. Oil is forced through the crankpin to properly lubricate the rod bearing assembly. 15.13 OIL PUMP for a complete explanation of the gerotor pump sets. The return gears pump oil back to the oil reservoir. Oil collected in the push rod areas of the cylinder heads ﬂows down the push rod cover. cylinder walls and ﬂywheel components. 9. Oil enters a hole in the end of the pinion gear shaft and travels to the right ﬂywheel where it is routed through the ﬂywheel to the crankpin. 14. 13. Oil also enters an intersecting passage in the gearcase cover. 12. Oil ﬂow is then routed to the crankshaft area. Return oil ﬁlls a cavity above the pump's return gears. 2. 16. through drain holes in the tappet blocks and into the gearcase. After providing lubrication to the gearcase components. A single piston oil jet cools the bottom of the piston with a spray of oil. passes through the ﬁltering medium into the central cavity of the oil ﬁlter. NOTE See 3. 4. Cross-drilled passages intersect the main feed galley and carry oil to both hydraulic lifters. Oil collected in the sump area returns to the scavenge section of the oil pump through a passage located in the rear section of the sump. 17.12 10.HOME OILING SYSTEM GENERAL 1. 3-48 2002 Buell P3: Engine . Oil ﬂow to the pump is accomplished by the scavenging effect of the pump and by the pressure created by the downward stroke of the pistons. Oil ﬂows through the feed galley in the crankcase to the tappet blocks and hydraulic lifters. The feed pump transfers oil from the inlet cavity through the external steel line to the oil ﬁlter mount. 8. the oil ﬂows to the left side of the oil pump. Oil is gravity-fed from the oil reservoir to the gerotor-style oil pump through a feed hose. 7. Oil ﬂows through the ﬁlter mount cavity to the oil ﬁlter. Feed oil to the rocker area is returned to the crankcase through a passage in the head and cylinder. 3. 6. The valve stems are lubricated by oil supplied through drilled oil holes in the rocker arms. Oil ﬂows up passages in the push rods to the rocker arm shafts and bushings.
oil is transferred from inlet to outlet as it is trapped between the rotating inner and outer gerotors. 9. feed and return. 15. housed in one pump body.HOME OIL PUMP GENERAL See Figure 3-90. 6. The inner gerotor has one less tooth than the outer gerotor. Gravity-fed oil from the oil reservoir enters the pump through the feed hose connector. 13. Make sure all oil hose clamps are tight and that hoses are not pinched or damaged. 14. 2. The oil pump seldom needs servicing. 10. 4.13 1 2 3 4 5 6 7 8 3. It is forced by the gerotor feed set through a hose to the oil ﬁlter. 12. 8. See Figure 3-90. In a gerotor gear set. 11. a0018x3x 3. 7. proper circulation of oil can be affected if the oil feed hose becomes clogged with ice or sludge. Before you disassemble an oil pump suspected of not producing adequate oil pressure. 3. The feed set distributes oil to the engine. In freezing weather. A gerotor-type gear set has two parts — an inner and an outer gerotor. be sure that all possible related malfunctions have been eliminated: 1. Pressure will be affected if oil is diluted. Both gerotors have ﬁxed centers which are offset to each other. Check for a grounded oil pressure switch wire or faulty switch if oil indicator light fails to go out with engine running. 5. Return oil from the ﬂywheel compartment is drawn back into the pump and is forced by the gerotor scavenge set back to the oil reservoir. Mounting Gasket Gear shaft Oil Line Assembly 90 ° Fitting O-ring Thrust Washer Retaining Ring Gerotor Return Set Separator Plate Gerotor Feed Set Cover 45 ° Fitting Sems Screw (2) TORX Screw (2) Rear Connector Fitting Figure 3-90. The oil pump consists of two gerotor gear sets. 15 9 10 11 12 14 13 1. the scavenge set returns oil to the tank/frame reservoir. 2. Oil Pump 2002 Buell P3: Engine 3-49 . Check level and condition of oil in tank.
7. Discard mounting gasket. 2. 7. d. (0. Blow out holes and oil passages with compressed air. See Figure 3-93. Remove and discard retaining ring. See ENGINE LUBRICATION SYSTEM section. 3 1. 3-50 2002 Buell P3: Engine . c.HOME REMOVAL/DISASSEMBLY NOTE Oil pump can be removed with engine in frame and without removing gearcase cover.004 in. 4. The SERVICE WEAR LIMIT between gerotors is 0. Replace gerotors as a set if clearance exceeds this dimension. Pump will drop with screws removed. a0024x3x 1 2 NOTE Loosen nut on oil ﬁlter hose connection and then remove pressurized hose. 2. See Figure 3-92. Inspect both gerotor sets for wear. Remove cover TORX screws. Remove and discard O-ring. 8. Carefully remove mounting screws and washers only. See Figure 3-90. Use a feeler gauge to determine clearance. 6. 3. 6. 2. Remove and discard oil ﬁlter. separator plate and both pieces of gerotor scavenge set off gear shaft. CLEANING AND INSPECTION 1. 3. See Figure 3-91. Feed Hose Connection Return Hose Feed Hose Clamp Cover TORX Screw (2) Oil Pump Return Hose Clamp Mounting Screw and Washer (2) Steel Line Connection Figure 3-91. Replace if necessary. 8. See Figure 3-91. 4 5 6 7 8 5. 3. Measure thickness of feed gerotors with a micrometer. 5. Disconnect feed hose and oil ﬁlter hose connection. 1. Check gear shaft teeth for damage or wear.102 mm). Mesh pieces of each set together as shown. Remove thrust washer and gear shaft. Remove clamp and detach return hose connection. b. 4. Replace gerotors as a set if they are not the same thickness. Oil Pump Hardware 9. Slide both pieces of gerotor feed set. Drain oil reservoir. Clean all parts in cleaning solvent. a. Lift cover off body.
Place cover onto pump body. If ﬁttings were removed. 8. Install new oil ﬁlter. 3. a0090x3x Inner Gerotor 2. use TEFLON® PIPE SEALANT or HYLOMAR® on ﬁtting threads.5 ENGINE LUBRICATION SYSTEM. 1.5 ENGINE LUBRICATION SYSTEM. Position thrust washer over end of shaft. 14. Install new retaining ring into groove in shaft. See Figure 3-90. 12. 3. 7. 4. Place outer gerotor over inner gerotor to complete scavenge set. See 1. Tighten to 70-80 in-lbs (8-9 Nm). Check engine oil level. Install a new O-ring into groove in pump body. 6.HOME ASSEMBLY/INSTALLATION NOTE Liberally coat all moving parts with clean engine oil to ensure easy assembly and smooth operation at start-up. Gerotor Wear Limits 6620 1 4 NOTE Use new hose clamps. See Figure 3-93. Wear Limit Outer Gerotor Figure 3-92. Insert inner gerotor of the gerotor scavenge set over gear shaft. Attach feed hose and oil ﬁlter hose connection. Gerotor Separator Plate Slot on Separator Plate Tab on Oil Pump Body O-ring Figure 3-93. 10. See Figure 3-91. See 1. Attach return hose connection. Install gear shaft through body. Place gerotor feed set over gear shaft. Place new mounting gasket in position. 5. 4. 9. Separator Plate Slots 3 2 2002 Buell P3: Engine 3-51 . 13. 1. See Figure 3-90. Tighten to 125-150 in-lbs (14-17 Nm). Add oil to correct level if needed. Install cover TORX screws. 2. 11. Secure pump to crankcase with mounting screws. Install gerotor separator plate by lining up slots on perimeter with tabs inside oil pump body. Attach clamp to hose.
HOME OIL FILTER MOUNT GENERAL a0091x3x 3.5 ENGINE LUBRICATION SYSTEM. 7. Install oil pressure indicator switch using OIL PRESSURE SENDING UNIT WRENCH (Part No. Filtered oil leaves the ﬁlter. 5. either end may be installed into the ﬁlter mount. 2. 3 4 5 CLEANING AND INSPECTION Thoroughly clean all parts in cleaning solvent. 2. ﬂowing past the check ball. 3. Blow out holes and passages using compressed air. See 1. NOTE The ﬁlter adapter has identical ends. b. See 1. Remove check ball and spring. 3. Oil is pressure-fed from the oil pump to the ﬁlter mount via rigid external steel line. Detach indicator lamp wire from oil pressure indicator switch. 6 Oil Pressure Indicator Switch Indicator Lamp Wire Oil Filter Mount (part of right crankcase half) Spring Check Ball Filter Adapter Hose to Oil Pump Hose from Oil Pump Figure 3-94. c. 4. Tighten to 50-70 in-lbs (6-8 Nm). Drain oil reservoir and remove ﬁlter. 6. Screw adapter into threaded hole. which turns off the oil pressure indicator lamp. Place spring and check ball into threaded hole at center of mount. The check ball in the ﬁlter adapter “opens” at 4-6 psi (28-41 kPa) oil pressure.14 1 See Figure 3-94. 1. 2. Install ﬁlter mount components. Install a new ﬁlter and ﬁll oil reservoir with proper oil. 8. Oil travels through the ﬁlter mount into the ﬁlter through the outer ﬁlter holes. Attach indicator lamp wire. Remove switch using OIL PRESSURE SENDING UNIT WRENCH (Part No. Remove ﬁlter adapter from ﬁlter mount. Push threaded end of ﬁlter adapter (with LOCTITE) against check ball to compress spring. Do not apply LOCTITE to adapter threads on ﬁlter element side. 4. Tighten to 8-12 ftlbs (11-16 Nm).5 ENGINE LUBRICATION SYSTEM. Adequate oil pressure activates the oil pressure indicator switch in the ﬁlter mount. See Figure 3-94. a. 5. 2 7 8 DISASSEMBLY 1. See Figure 3-94. Oil Filter Mount Assembly ASSEMBLY NOTE Use TEFLON PIPE SEALANT or HYLOMAR on all ﬁttings installed to oil ﬁlter mount. 1. Apply several drops of LOCTITE® thread locker 243 (blue) to last few threads on that end of the ﬁlter adapter which is installed into ﬁlter mount. HD-41675). HD-41675). 3. 3-52 2002 Buell P3: Engine .
it also contains a check valve. See Figure 3-96. b. a. 5. Check lifter roller freeplay.0203-0.5 CYLINDER HEAD.0152-0. (0. follow the surface of the revolving cam. the assembly operates with minimal lifter clearance.008-0. When a lifter is functioning properly. a. which allows the unit to ﬁll with engine oil. Accurately measure lifter bore inner diameter with a gauge. a.0015 in.5 CYLINDER HEAD. Soak lifters in clean engine oil.559 mm). See 3. It is normal for lifters to click when engine is started after standing for some time. Remove both valve hydraulic lifters.0508 mm). Remove push rod cover. Remove screws.15 Piston Oil Oil Check Valve Roller REMOVAL b. 3.203-0. 2002 Buell P3: Engine 3-53 .0030 in. (0. The lifter assembly consists of a hydraulic lifter and roller.0381 mm). Remove the lower rocker cover. 5.026 in. CLEANING AND INSPECTION 1.0010 in. Lifter Assembly (Typical) Fit a new lifter and/or replace crankcases if clearance exceeds SERVICE WEAR LIMIT of 0. The up-and-down motion produced is transmitted to the valve by the push rod and rocker arm. b. b.0008-0. Remove lifters from crankcase bore using a thinbladed screwdriver. This is necessary to allow units to compensate for various expansion conditions of parts and still maintain correct clearance operation. 3. under compression force from valve spring. The lifter and roller. Discard parts. Blow dry with compressed air. 1. Clean all dirt from around crankcase. Clearance should be within 0. Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0. Lifters are functioning properly if they become quiet after a few minutes of engine operation. Mark the location and orientation (front/back) of each lifter. Roller clearance on pin should be within 0. a. Remove cylinder head assembly. Remove gasket and o-rings. Clean all parts. (0. See 3. The lifter contains a piston (or plunger) and cylinder. 2. (0.0254 mm).00060. (0. Keep covered until assembly. Inspect valve lifters for excessive clearance in guide. Check lifter roller end clearance. Pull each push rod upward through top of cylinder head.HOME HYDRAULIC LIFTERS GENERAL See Figure 3-95. Blow loose particles from area with compressed air. Hydraulic lifters have a deﬁnite leakdown rate which permits the oil in the lifters to escape. 4. except roller/lifter assembly. End clearance should be within 0.022 in. thereby reducing clearance in the valve train. b.076 mm). thoroughly in solvent. Remove anti-rotation screws.0020 in. Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0. (0. Remove push rod cover. NOTE Inside and outside micrometers used for measuring tappets and tappet guides must be calibrated to ensure accurate readings. The unit automatically compensates for heat expansion to maintain a no-clearance condition. a. a0092x3x 3. Figure 3-95. 2.660 mm). c. 4.
4.Rotation Screw Figure 3-96. See Figure 3-96. 6. 1 a0093x3x 2W 1W 2 1. 3. 5. Place new o-rings on top of push rod cover. Apply a liberal amount of engine oil to each lifter assembly (especially the roller needles) for smooth initial operation. 4. Push Rod (exhaust) O-ring Push Rod Cover Screws (4) Push Rod Cover Push Rod Cover gasket Hydraulic Lifter (tappet) Anti. from the cylinder will be installed on the base circle of the cam. Rotate engine so that both lifters. Install push rods. a. anti-rotation screws cannot be inserted. Slide new gasket cover over bottom of push rod cover. 2. Secure lifters in place. Install screws through holes in push rod cover into tapped holes in crankcase. Install anti-rotation screws with washers in the holes in lifter block. 5 6 7 1. 6. 2. 7. 3. If the lifter is installed incorrectly. lower and upper rocker covers.5 CYLINDER HEAD. See Figure 3-97. a. cylinder head. Position push rod cover onto crankcase. Insert lifter into bore in crankcase. Rotate lifter so that ﬂats at upper end of lifter face the front and rear of the engine. Tighten screws evenly to 30-40 in-lbs (3-5 Nm).HOME INSTALLATION a0029x3x 1 2 3 4 1. Base Circle (lowest position) Cam Lobe (maximum lift) Figure 3-97. 8. See 3. c. Install push rod cover. Valve Lifter Service d. b. 2. b. Base Circle 3-54 2002 Buell P3: Engine . Tighten anti-rotation screws to 55-65 in-lbs (6-7 Nm). 8 5.
HOME GEARCASE COVER AND CAM GEARS GENERAL Read the complete gearcase section carefully before you begin any service work. a0030x3x 3 4 6 18 17 16 1 15 10 3 6 5 4 4 2 14 13 11 12 9 8 7 1. 15. Gearcase Cover & Cam Assembly 2002 Buell P3: Engine 3-55 . 8. 11. 12. 7. Changing one component can affect many others. 5. 4. 9. 13. 2. 14. 17.16 For the gearcase components to operate at their optimum. 3. Crankcase Half Dowel Pin Inner Camshaft Gear Bushing “W’ Cam Gear Set Oil Pump Drive Gear “W” Cam Pinion and Drive Gear Set Nut Gear Shaft Pinion Bushing Cam Gear Shaft Outer Bushing Key Camshaft Cover Gasket Gear Cover Seal Sems Screw Oil vent hose ﬁtting Clamp Vent Hose Outer Bushing Figure 3-98. 6. 18. all components must be properly ﬁtted and matched. 10. 3. 16. It is important to know and understand all inspection procedures and how components interact.
a0075x3x Identify cams by stamped number 2. Gear diameter should be measured in at least two places 90° apart. Do not use this dot to select pinion gear size. NOTE Nut is secured by LOCTITE® thread locker 262 (red) on the nut threads. Measure the gear diameter with a micrometer over 0. When cam gears are replaced. Thoroughly clean gearcase compartment. NOTE Prior to changing any cam gears. 3. Remove hydraulic lifters. and Selection See Figure 3-99. 6. Place a pan under gearcase to collect oil. HD-38361) Figure 3-100. Remove any parts that will interfere with gearcase disassembly. Remove cover screws. Record readings. See Figure 3-98. Use GAUGE PIN SET (Part No. Cam Identiﬁcation 7. Cam lobes are stamped with a number (1 or 2) followed by a letter (“W”). Check for minimum cam gear end play. Gauge Pin Set (Part No. If damaged. Remove cam gears. replace both gears as a pair. For location of cam gear color codes. NOTE On ﬂywheel pinion shaft. Discard old gasket. NOTE If cover does not come loose on removal of screws. gearcase cover and gears in solvent to remove oil and carbon deposits.15 HYDRAULIC LIFTERS.108 in. check gear shaft ﬁt within corresponding bushings. 9. Slide pinion gear and oil pump drive gear off pinion shaft.HOME REMOVAL/DISASSEMBLY 1. 4. Thoroughly clean area around gearcase cover and tappets. 3. Pinion gear and large gear on intake cam are one size only. 7673 CLEANING AND INSPECTION 1. No selective sizing is possible.743 mm) diameter gauge pins on opposite sides of the gear. Remove push rods. Remove cam position sensor and rotor from gearcase cover. See 3. 8.5 CYLINDER HEAD. always use the same color code as found on gears being replaced to ensure that the gear operation remains as quiet as possible. Measuring Gear Size Cam gears are individually selected for each speciﬁc gear cover through sophisticated computer-aided measuring techniques in a controlled environment. Never pry cover off. Blow loose dirt from crankcase with compressed air. This dot identiﬁes the pinion shaft inner race size. The number (1 or 2) identiﬁes the cam location/function and the letter (“W”) indicates model year application: 2W=Intake 1W = Exhaust See Figure 3-100. See Table 3-12. Remove nut. 2W Figure 3-99. 3-56 2002 Buell P3: Engine . See 7. Inspection. Each gear is assigned an individual color code based on its diameter (measured with gauge pins). The pins are of the proper size to ﬁt between the contacting surfaces of the gear teeth. Worn bushings can cause excessive backlash. see Figure 3-101. 5. Compare the previously measured diameter of each gear with the speciﬁcations (listed in inches) shown in the table to determine amount of wear on gear teeth. See 3. a paint dot is located on the shaft perimeter near the centerline of the keyway. HD-38361) when measuring pinion and cam gear sizes. (2. Blow out all cover oil passages and bushings with compressed air. 2.8 IGNITION MODULE/ CAM POSITION SENSOR. Clean old gasket material from gearcase and cover faces with cleaning solvent. tap lightly with a plastic hammer. Carefully remove gearcase cover. Cam and Pinion Gear Identiﬁcation.
9029 (48.9025-1.9025-1.9019 (48.333) 1.9024 (48.9015-1.323-48. 3.310-48. 2.321) 1. & POSITION COLOR CODE (1 paint dot) RED WHITE GREEN 2 INBOARD Intake 1.9024 (48.9020-1.310-48.298-48. Cam and Pinion Gear Color Code Location and Timing Mark Indexing Table 3-12. 4.298-48.9019 (48.308) 2 OUTBOARD Intake 1 3 Exhaust 1.323-48.308) Pinion 2002 Buell P3: Engine 3-57 .321) 1.9015-1.HOME 7687 2 1 3 4 1.9020-1. Cam and Pinion Gear Color Code and Diameter GEAR NO.333) 1.9029 (48. Exhaust Cam Gear (1W) Intake Cam Gear (2W) Pinion Gear Color Code Figure 3-101.
7674 806a Bushing and Bearing Puller (Part No. Removing Bushing 2.1092 mm) SERVICE WEAR LIMIT 0. See Bushing Reaming. HD-33416) Figure 3-104. Cam Gear Bushing Right Crankcase Half 2.076 mm) 0. See Figure 3-102. Cam Gear Bushing Installed in Crankcase 3. HD-95760-69A) to remove bushings from gearcase cover and crankcase. to be installed in right crankcase half. Inspect each bushing against its corresponding cam gear shaft or pinion gear shaft. For quiet-running gears. 7706 2 1. 3. Using an arbor press. HD-33416). and CAMSHAFT NEEDLE BEARING (Part No. must be positioned in crankcase bore with its oiling slot at crankcase slot.0178-0. See Figure 3-103. 2. Use a BUSHING AND BEARING PULLER (Part No.0584-0.1270 mm) Figure 3-102.0007-0. Position each bushing so the oiling slot is at the 3 o’clock position within the gearcase cover bore. install each bushing in its gearcase cover bore so that bushing shoulder contacts cover boss. 3 2. Bushings are press ﬁt in gearcase cover and crankcase. HD-97273-60) install each bushing in its crankcase bore so that bushing shoulder contacts crankcase boss. Bushing Installation NOTE Installing and reaming crankcase and gearcase cover bushings may alter the center distances between mating gears and may result in an increase in gear noise. (0. the gears should be matched to the center distances. (0.0023-0.0559 mm) 0. Using an arbor press.0022 in. UNIVERSAL DRIVER HANDLE (Part No. 1 7678 Oiling slot must be at 12 o’clock position CAM GEAR BUSHINGS IN RIGHT CRANKCASE HALF 1.HOME Bushing Inspection and Removal 1. Arbor Press 3-58 2002 Buell P3: Engine . Figure 3-103. CAM GEAR BUSHINGS (EXCEPT INTAKE BUSHING) IN GEARCASE COVER 1.003 in.0050 in. HD95760-69A) Table 3-13. Each cam gear bushing. HD-97273-60 Universal Driver Handle (Part No. See Figure 3-98. See Bushing Reaming. Gear Shaft Speciﬁcations GEAR SHAFT Cam Pinion CORRECT CLEARANCE 0. See Table 3-13. See Figure 3-104.0043 in. Gearcase Camshaft Bushing Installer (Part No. 2 1 1. After you install a new bushing in right crankcase half. line-ream the bushing to correct size. 2. (0. ream the bushing to correct size. After you install a new bushing in gearcase cover. (0.
therefore. 1. After you install a new bushing in gearcase cover.20 in. Drilling Dowel Pin Hole Installing and reaming crankcase and gearcase cover bushings may alter the center distances between mating gears and may result in an increase in gear noise. The intake cam gear bushing must be installed in its gearcase cover bore using an arbor press. Although the original pinion shaft bushing is not “pinned. Press bushing into cover bore until bushing is ﬂush with cover boss. See Figure 3-98. Bushings in right crankcase half serve as pilots for reaming gearcase cover bushings and must. PINION SHAFT BUSHING IN GEARCASE COVER 1. 0. See Bushing Reaming. After reaming any bushing. See Figure 3-98. (7. 4. Front Intake Cam Gear Bushing Gearcase Cover Slot 2. Figure 3-105. Rear Intake Cam Gear Bushing Installed in Gearcase Cover 2. from possible rotation within the cover bore. 31 hole. See Bushing Reaming. Using an arbor press. It may be necessary to make a second pass with reamer to attain proper ﬁt. be reamed to size ﬁrst. You will need to orient the bushing in a speciﬁc position of rotation within the cover bore according to the following procedures: 1. See Figure 3-106.281 in. by installation of a dowel pin. Bushing Reaming NOTE ● Replacement bushing requires dowel pin hole Figure 3-106. See Figure 3-105. install pinion shaft bushing in its gearcase cover so that bushing is ﬂush with cover boss. check shaft ﬁt in the bushing.08 mm) below the bushing face. the gears should be matched to the center distances.137 mm) deep. Align slot in bushing with slot in gearcase cover boss. ● ● 2002 Buell P3: Engine 3-59 . Carefully peen edges of hole to lock the pin in place. Drive a new dowel pin no more than 0.HOME INTAKE CAM GEAR BUSHING IN 7684 GEARCASE COVER. centering the drill bit on the cover bore circle (hole is drilled half in bushing OD and half in cover bore ID). 7682 3. line-ream the bushing to the correct size. 2. (5. Position bushing over bore of gearcase cover with chamfered edge downward and slot upward. line-ream the bushing to the correct size. After you install a new bushing in gearcase cover. at top side of boss (side toward top of gearcase cover). For quiet-running gears.” the replacement bushing must be secured. There is no need to orient this particular bushing in any speciﬁc position of rotation within the gearcase cover bore. Drill a No.
Figure 3-107. B-43988) onto gearcase side of crankcase half. Bushing to be reamed must be oriented as shown in Figure 3-103. Separate gearcase cover from right crankcase half. 5. Separate two halves of crankcase. which is in line with exhaust bushing to be reamed in gearcase cover. securing with a minimum of three mounting screws. securing with a minimum of three mounting screws. Tighten bolts securely. Position CAMSHAFT BUSHING REAMER PILOT (Part No. EXHAUST GEAR BUSHING IN GEARCASE COVER NOTE Newly installed cam gear bushings in the gearcase cover must be line reamed. If crankcase halves are not separated on your motorcycle. See Figure 3-98.HOME CAM GEAR BUSHINGS IN RIGHT CRANKCASE HALF 1. 4. using the right crankcase half as a pilot for the reamer. upper right and lower left indexing holes in pilot must be placed over dowels in crankcase half. 2. Turn reamer clockwise through bushing in cover until reamer bottoms. Place right crankcase half on ﬂat surface with gearcase side upward. using both the right crankcase half and Part No. Turn reamer clockwise through bushing in gearcase cover until reamer bottoms. Bushings to be reamed must be installed in gearcase cover as described in BUSHING INSTALLATION. With reamer inserted into bushing in right crankcase half. Failure to wear safety glasses or goggles could result in death or serious injury. Failure to wear safety glasses or goggles could result in death or serious injury. Blow out all oil passages using compressed air. 6. removing all metal chips/shavings. Identify the previously reamed intake cam gear bushing in right crankcase half. to establish correct clearance and to ensure proper alignment. If crankcase halves are not separated on your motorcycle. Continue turning reamer clockwise while extracting reamer from bushing. Insert two bolts (supplied with pilot) through two remaining holes in pilot. use a spare right crankcase half to perform the following line reaming procedures. Blow out all oil passages using compressed air. Safety glasses or goggles must be worn while removing metal chips/shavings. Blow out all oil passages using compressed air. to establish correct clearance and to ensure perfect alignment. Pull reamer out opposite side of crankcase half. Then give reamer one complete clockwise turn to size the bushing. Thoroughly clean right crankcase half. Insert REAMER (Part No. 1. 3. PINION SHAFT BUSHING IN GEARCASE COVER NOTE A newly installed pinion shaft bushing in the gearcase cover must be line reamed. Safety glasses or goggles must be worn while removing metal chips/shavings. Insert REAMER (Part No. Thoroughly clean gearcase cover. 5. which has been disassembled from left crankcase half. See Figure 3-98.B-43988) 2. Intake cam gear bushing must be installed in gearcase cover as described in BUSHING INSTALLATION. 5. 2. 1. 4. use a spare right crankcase half to perform the following line reaming procedures. Repeat line reaming operation if necessary. Thoroughly clean gearcase cover. HD-94812-87 as pilots for the reamer. If crank- INTAKE CAM GEAR BUSHING IN GEARCASE COVER 3-60 2002 Buell P3: Engine . Inspect bushing for proper cam gear shaft ﬁt. 7739 Camshaft Bushing Reamer Pilot (Part No. Attach gearcase cover to right crankcase half. 3. See Figure 3-107. removing all metal chips/shavings. 4. HD-38871-2) through the previously reamed cam gear bushing in right crankcase half. Insert the shank end of REAR INTAKE CAMSHAFT BUSHING REAMER (Part No. removing all metal chips/shavings. 3. Reaming Cam Gear Bushing in Right Crankcase Half NOTE A newly installed intake cam gear bushing in the gearcase cover must be line reamed. attach gearcase cover to right crankcase half. Inspect bushings for proper cam gear shaft ﬁt. HD94804-67) through gearcase side of this bushing. which has been disassembled from left crankcase half. Continue turning reamer clockwise while extracting reamer from bushing. Detach reamer from handle. using the right crankcase half as a pilot for the reamer. Separate gearcase cover from right crankcase half. Continue turning reamer clockwise through bushing until smooth shank of reamer passes through hole in pilot. and into threaded holes of crankcase half. Repeat line reaming operation if necessary. HD-38871-2) through pilot hole and into bushing while turning reamer clockwise. to establish correct clearance and to ensure perfect alignment. Then give reamer one complete clockwise turn to size the bushing. if not already accomplished.
1 1. Repeat line reaming operation if necessary. Inspect bushing for proper pinion shaft ﬁt. Insert PINION SHAFT BUSHING REAMER (Part No. 1.HOME case halves are not separated on your motorcycle. securing with a minimum of three mounting screws. 2. See Figure 3-108. 2. Attach gearcase cover to right crankcase half. Separate gearcase cover from right crankcase half. which has been disassembled from left crankcase half. 2 3 4 4. Thoroughly clean gearcase cover. HD-94812-1) through the pilot. 3. Pilot (Part No. See Figure 3-98. Then give reamer one complete clockwise turn to size the bushing. HD-94812-87) Reamer (Part No. Remove pilot from right crankcase roller race. use a spare right crankcase half to perform the following line reaming procedures. Continue turning reamer clockwise while extracting reamer from bushing. Install PINION SHAFT BUSHING REAMER PILOT (Part No. 3. 4. Blow out all oil passages using compressed air. HD-94812-1) RIght Crankcase Gearcase Pinion Bushing Figure 3-109. 3. removing all metal chips/ shavings. Pinion shaft bushing must be installed in gearcase cover as described in BUSHING INSTALLATION. Failure to wear safety glasses or goggles could result in death or serious injury. 7715 2. Reamer (Part No. 7716 5. See Figure 3-109. HD-94804-67) RIght Crankcase Half Gearcase Intake Cam Figure 3-108. Line Reaming Pinion Shaft Bushing 2002 Buell P3: Engine 3-61 . 1 2 3 4 5 1. 5. Line Reaming Intake Camshaft Bushing Safety glasses or goggles must be worn while removing metal chips/shavings. HD-94812-87) into right crankcase roller bearing. 4. Turn reamer clockwise through bushing in gearcase cover until reamer bottoms.
b. Tighten nut to 19-21 ft-lbs (26-29 Nm) plus an additional 15 ° to 17 ° rotation. See Figure 3-98. See Figure 3-110. c. Slide pinion gear over shaft key and against oil pump drive gear. Install CRANKSHAFT LOCKING TOOL (Part No. Align keyway in ID of pinion gear with shaft key. b.HOME ASSEMBLY/INSTALLATION 1. Slide oil pump gear drive gear over pinion shaft. 3. Aligning Pinion Gear c. Install a new seal and new dry gearcover gasket on crankcase. a. Crankshaft Locking Tool (HD-43984) 3-62 2002 Buell P3: Engine . 7686 Figure 3-111. a. d. with two screws. Drive gear must align with shaft key. See Figure 3-111. Install shaft key into pinion shaft slot. d. properly aligning timing marks of cam gears and pinion gear. Install oil pump drive gear and pinion gear on pinion shaft. 3 4 5 Pinion Shaft Timing Mark on Pinion Gear Keyway Shaft Key Oil Pump Drive Gear Figure 3-110. shafts. a0078x3x 1 2 See Figure 3-98. Clean threads on pinion shaft and nut. 2. 5. the exhaust cam gear must be installed before the intake cam gear is installed. Liberally apply engine oil to bushings. NOTE Because of the larger diameter additional gear (which meshes with the pinion gear) on the outboard end of the cam. See Figure 3-101. 3. 1. and gears. Install nut to pinion shaft. Install nut. over pinion shaft. 4. 4. HD-43984) to gearcase with “Side B” facing out. Install all cam gears into bushings of right crankcase half. Apply several drops of LOCTITE® thread locker 262 (red) to last few threads of nut. 2.
exhaust system components. 7. 5 2 4 Figure 3-112. Secure cover to crankcase half with 7 socket head screws. etc. See Figure 3-112.e. Install hydraulic lifters and push rods.HOME 5. Install cam position sensor and rotor in gearcase cover. Install any components removed to gain access to gearcase (i. Compare cam gear end play measurements with the SERVICE WEAR LIMITS. Checking Cam Gear End Play 2002 Buell P3: Engine 3-63 . 9. Check cam gear end play for each cam gear as follows: a. 7696 6 7 3 1 6. 7. b. See 3. Gently pry the cam gear toward the gearcase cover using a ﬂat blade screwdriver. d. Use torque sequence as shown in Figure 3-112. air cleaner. Tighten screws evenly to 80-110 in-lbs (9-12 Nm). See Figure 3-113.15 HYDRAULIC LIFTERS. Measure gap between bushing (in crankcase half) and cam gear shaft thrust face (shoulder) using a feeler gauge. Install gearcase cover over all gears and onto right crankcase half. This is cam gear end play.). c. 8. Gearcase Cover Mounting Screw Torque Sequence 7683 Figure 3-113.8 IGNITION MODULE/ CAM POSITION SENSOR. Turn engine over until lobe of cam gear being checked is pointing toward its respective tappet guide hole. Make repairs as required if end play does not meet speciﬁcations.
3 STRIPPING MOTORCYCLE FOR ENGINE REPAIR/ REMOVAL.8829-2.0.1095 .8575 2.6543 2.5273-2.16 GEARCASE COVER AND CAM GEARS. do not lay engine on primary side. After engine has been removed from chassis.1085 0.0. Tighten to 190-210 ft-lbs (258285 Nm).0.6289-2.1135 . Remove gearcase cover.1045 0. use a thicker shim for more end play.0. 3. Choose shim from Table 3-14.0250.9083 5. NOTE Use a thinner shim for less end play.1035 . 2.1025 0.127 mm).1015-0. b. 3-64 2002 Buell P3: Engine . Rotate and push on sprocket shaft while reading dial indicator. This includes inspecting and repairing cylinder head. gearcase and transmission. See 3. securely fasten it to a stand or workbench. 1.HOME CRANKCASE GENERAL If engine is removed from chassis. Then rotate and pull on sprocket shaft while reading dial indicator.1065 0.8067 2.8321-2.1055 . It is recommended procedure to overhaul engine if removed. If ﬁtting is damaged. Install the nut and sprocket.1125 0. preload sprocket shaft bearings. a. Check ﬂywheel end play.1115 .6035 2.0. 0. Replace bearing inner shim if difference (end play) in indicator readings is not 0.1075 . Placing engine on primary side will damage clutch cable end ﬁtting. 4.1005 0.0975-0.4765-2.0995 . Checking Flywheel End Play Table 3-14.0.7305-2.5781-2. (0.1145 MM 2. Flywheel End Play Shims PART NUMBER 9155 9142 9143 9144 9145 9146 9147 9148 9149 THICKNESS IN.6797-2.001-0.1105 0.5527 2. See Figure 3-114. Create a suitable tool by welding two handles to an old engine sprocket nut.0985 0.17 ADJUSTMENT/TESTING Flywheel End Play Before completely disassembling crankcases.7051 2. a0135x3x 3. clutch cable must be replaced. cylinder. Figure 3-114. Remove engine from chassis to repair pinion shaft bearing or sprocket shaft bearing.005 in.0.7559 2. Attach a dial indicator to gear side crankcase with indicator stem on end of gearshaft.5019 2. See 3.7813-2. To obtain an accurate ﬂywheel end play reading. c. check ﬂywheel end play.
After removing cylinder.3/8 I. Remove gearcase components. 3. Lifting or moving crankcase by grasping studs will cause cylinder stud damage. X 13/16 O. See 3.D. Remove cylinder head.16 GEARCASE COVER AND CAM GEARS. Crankcase Set Bottom Case T40 TORX Bolt – 5/16-18 X 3-1/2 in. 9. 7. 10. See Figure 3-115. 7. 2.HOME DISASSEMBLY Crankcase Halves 1. 6. Remove cylinder and piston. (1) Nyloc.2 PRIMARY CHAIN. Wear eye protection and make certain set-up is stable. 4. Remove starter motor. See 3. 8.3/8-16 Hex Socket Head Screw – 5/16-18 X 2-1/2 in. Tap crankcase with plastic mallet to loosen and separate the halves. 6. 3. install plastic or rubber hose over cylinder studs. The pressure 2002 Buell P3: Engine 3-65 .6 CYLINDER AND PISTON. a0103x3x 9 10 11 1 2 3 2 3 2 3 2 3 8 3 7 8 6 4 5 8 3 8 3 8 3 8 3 8 3 8 3 3 2 3 1. long (9) Rear Isolator Screw (4) Washer (4) Figure 3-115.7 STARTER. See 3.5 CYLINDER HEAD. See 3. Remove primary cover and primary drive/clutch components. See 6. 2. Hex Locknut . 4. long (5) Washer 21/64 x 9/16 x 19 (14) Hex Socket Head Screw – 3/8-16 X 4-1/2 in. Remove oil pump. Crankcase Hardware The next step requires using a press.D. See 5. 11. long (1) Spacer (1) Washer . 8. Remove screws and rear engine mount bolts securing crankcase halves together. 5. 5.13 OIL PUMP.
15. Press on end of sprocket shaft with arbor press until ﬂywheel assembly is free from crankcase half. Inadequate safety precautions could result in death or serious injury. Gearshaft bearing will remain on ﬂywheel pinion shaft. 13. Remove retaining ring. 3. Gear Shaft Bearing Retaining Ring Outer Bearing Race Crankshaft Half Figure 3-117. Mount the left crankcase half and ﬂywheel assembly on a press table. 9. If it is necessary to remove either the pinion shaft bearing or sprocket shaft bearing. HD-44385). 14. See Figure 3-118. 2. Pressing Flywheel from Crankcase a0084x3x 1 2 10 4 5 6 7 8 9 3 1. 11. proceed as follows: Figure 3-116. Do not drive ﬂywheel assembly from crankcase half as ﬂywheels may be knocked out of alignment. 5. and bearing may be slipped off pinion shaft. See Figure 3-116. Oil Seal Bearing Assembly Crankcase Half Connecting Rod and Flywheel Assembly Inner Race Retaining Ring 12. Pull sprocket shaft bearing with SPROCKET SHAFT INNER 3-66 2002 Buell P3: Engine . Crankcase and Flywheel Assembly 10. 7689 Press on end of sprocket shaft NOTE See Figure 3-117. Place ﬂywheel assembly in FLYWHEEL SUPPORT FIXTURE (Part No. supporting crankcase on parallel bars. 6. 4.HOME involved could cause parts to “ﬂy out” with considerable force.
To remove pinion shaft inner race. Left Crankcase Half Universal Driver (Part No. HD34902B). Four sizes of pinion bearings are available. A running clearance of 0. 3. (0. during engine rebuild. use WEDGE ATTACHMENT for CLAW PULLER (Part No. 2. Sprocket Outer Shaft Race Removal 7671 Bearing Race Remover/ Installer (HD-34902B) 7671 End Cap (HD-34902-7) Bearing Remover (HD-44404) 1 Flywheel Fixture (HD-44385) 2 3 Figure 3-118. Pinion bearing selection at the factory. 2. HD-34902-7). See Figure 3-120. 12. 13. Removing Sprocket Shaft Roller Bearing 1.HOME TIMKIN BEARING REMOVER (Part No.0008 in. Use CRANKSHAFT BEARING TOOL (Part No. 3. HD-34902-7) Wedge Attachment for Claw Puller (Part No. Pulling Pinion Shaft Inner Race 2002 Buell P3: Engine 3-67 . Bearing Race Remover/Installer (Part no. or replacement of crankcase set or ﬂywheel assembly is based on the largest measured outside diameter (OD) of the inner race and the smallest measured inside diameter (ID) of the outer race (crankcase bushing).0002-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. HD-94547-101) to remove sprocket shaft outer races. HD-34902B) and END CAP (Part No. HD-94547-101) Figure 3-119. HD95637-46A) Figure 3-120. 7709 1 2 3 1. HD-95637-46A) with BEARING RACE REMOVER/ INSTALLER (Part No. Apply heat to race to aid removal. HD-33416) Crankshaft Bearing Tool (Part No. HD-44404) and BEARING RACE REMOVER/INSTALLER (Part No. See Figure 3-119. HD34902B End Cap (Part No.0051-0.
(39.HOME 14. (31.5672 in. See Figure 3-123.7398-31.5648-1.7510 mm) 1. Installed inner races are identiﬁed at the factory as shown. NOTE The different sizes of crankcase sets and ﬂywheel assemblies will not have separate part numbers.2492 in. (39.7510-39.7449-31.7408-39.2498-1. 2 or 3 pinion outer race. Pinion bearings are identiﬁed as shown. Factory Outer Race Sizes Paint Dot a0133x3x A – Roller OD cannot be measured to required accuracy with micrometer RACE OD 1.5646-1. IDENTIFICATION* 1 2 3 1 2 3 Inner Race * Stamped number inside crankcase near race SERVICE WEAR LIMIT: 1. BEARING SELECTION See Table 3-15. (31.7500 mm) 1.7561 mm) a0131x3x CLASS STAMPED NO. Replacement ﬂywheel assemblies will have either a class A or B inner race. Factory Inner Race Sizes Smallest * Package color Figure 3-123. ID Right Crankcase Half a0134x3x Outer Race Stamped Class No. a replacement crankcase set may have a class 1.7459-39. 16. (39. (39.7459 mm) 1.5650 in. Outer races are identiﬁed at the factory as shown. That is. See Figure 3-122.5650-1.5648 in.7297 mm) Figure 3-121.2500 in. Pinion Shaft Bearing Selection. 15. Bearing Identiﬁcation 3-68 2002 Buell P3: Engine . (31.2496-1.7449 mm) CLASS A B IDENTIFICATION* White Green ROLLER OD (A) Largest IDENTIFICATION* Red Blue White (Grey) Green * Paint dot on end of spline SERVICE WEAR LIMIT: 1.2498 in.8069 mm) Figure 3-122.5652 in. RACE ID 1. measure both races to conﬁrm correct bearing ﬁt. Select bearings using the identiﬁcation information given for inner and outer races and bearings. NOTE If either inner or outer race show wear. See Figure 3-121.
3.62 mm) 1. Apply heat to race to aid removal.560" (39.5672 in. (39. continue at Step 5.1 mm) 1. (0.00 (25.5651 in.8069 mm). (0.HOME 1. Check measurements against these speciﬁcations: 1.5672 in.0002 in.8069 mm) or the required lapping to remove wear marks would enlarge bore beyond 1.5646 . If largest measurement is 1. (31.83 mm) Press the outer race from the right crankcase.00 (25.754 mm).4 mm) b.4 mm) Pinion inner race installation 5. Inner Race Location Taper: within 0.00" (50. (0. 9.145 in. Roundness: within 0.0002 in. For example purposes. 5. Press new outer race into crankcase ﬂush with inside edge of cast-in insert. Assemble crankcase halves. Figure 3-124. 2002 Buell P3: Engine 3-69 8.00" (25.. (0. Pinion outer race removal . c. 5/16" (7.560" (39.94 mm) DRILL 1.39. See Figure 3-124.760 mm). See Table 3-15. Lap race until all wear marks are removed. To keep sprocket shaft and pinion shaft bearings aligned the lap must be supported by an adaptor or pilot in the left crankcase half. See Figure 3-125. (0. If roundness or taper do not meet speciﬁcations. The new inner race must be ground by a competent machinist to OD dimension range for the ﬁnished lapped ID of the outer race. HD-34902B) and END CAP (Part No.0051 mm) Figure 3-125.94 mm) DRILL 1.75 mm) NOTE The next step requires lapping the outer race.0051 mm) Taper: within 0. If the largest measurement is larger than 1.262" (32. The new outer race must be lapped slightly to true and align with left case bearing and to meet the following speciﬁcations. (39. b. (39. Pinion Shaft Inner Race Flywheel (gear side) 6. This requires an inner race OD range of 1.7408 . Pinion Shaft Bearing Tools 1.5672 in.4 mm) a0109x3x Pinion outer race installation 2. (39.50" (139. When the tool bottoms against the ﬂywheel.8069 mm) or less.05 mm) 1. Use a dial bore gauge to measure and record ID of outer race. continue lapping until speciﬁcations are met. The following example illustrates how to determine the required inner race OD. a. 2.31 mm) 1.145" (29. See LAPPING ENGINE MAIN BEARING RACES.8069 mm) or less Roundness of ID: within 0.62 mm) 1.1. Press new inner race on pinion shaft as shown.50" (38.5672 in. ID: 1. go to Step 5. 2.0002 in.0051 mm) Surface ﬁnish: 16 RMS NOTE Always use the smallest outer race ID measurement and the largest OD inner race measurement when selecting bearings.0002 in.135 in.083 mm)1. For necessary dimensions for constructing a press-on tool see Figure 3-124.135" (28.7561 mm) Roundness: within 0. 1.0051 mm) Taper: within 0. (0. See LAPPING ENGINE MAIN BEARING RACES.272" (32.2504 in.0002 in.0051 mm) Surface ﬁnish: 16 RMS 2 1 a0283x3x 7.740 .2496-1. Take four measurements on ID where bearing rollers ride.187" (4. Measure and record ID of race at four places. Pull inner race from pinion shaft using WEDGE ATTACHMENT for CLAW PULLER (Part No. (39.5672 in.0051) a.75 mm) 5/16" (7. a.7 mm) Largest ID measured: 1. Dimensions are shown for fabrication of tools used in pressing the outer race into or out of crankcase. (39.829 mm) 1. . The ﬁnished inner race must meet these speciﬁcations. 4. HD-34902-7).8 mm) . See Table 3-15. correct inner race location is automatically established. suppose the smallest outer race ID measurement is 1. cover the cam bearings with masking tape to prevent debris from entering bearings.08 mm) 1. See Figure 3-125. If all speciﬁcations are met. continue at Step 7 to remove and size inner race. If lapping increased bore ID to larger than 1.0002 in.187" (4. HD-95637-46A) with BEARING RACE REMOVER/ INSTALLER (Part No. (29.31.5652 in. (28.
2506 1.781 mm 1. in.Green Gray Green White.791 mm mm FACTORY COLOR CODE Green White 3-70 2002 Buell P3: Engine .766 mm 1.755 mm 1. (31.776 mm 1. 39. 39.2499 in.756 mm 1.755 31.2502 in.2510 1. 31.755 mm 1.2514 in. With a 1.1.750 mm mm 1.2508 1.2498 1.771-39.745 31.5654-1.5660-1.Green Gray White. Measure OD at four places.2502 1. 39. Table 3-15.756-39.5666 in.747 mm) OD. 39.5662-1.786 mm 1.Green Gray White.766-39.2512 in.Green Gray 1.Green Gray White. INNER RACE OD (In) 31. Grind inner race.797-39.2516 in.5651 in. This will prevent grinding outer race undersize and gives a more easily achieved tolerance range.5650-1.5664 in.807 mm 1.786 3.5658 in. 39.740 31. 31. 39.Green Gray White.765 31.Green Gray White. Pinion Shaft Bearing Selection FACTORY STAMP ED NUMBER OUTER RACE ID BEARING SIZE AS IDENTIFIED BY COLOR CODING over 1.2504 in.761 mm 3 2 1 1. b.2508 1. in. 39.797 mm 1.746-39. 39. 39.2510 in. (31.2500 in.780 31.2496.760 mm mm mm 1.79131.5668-1. 39.780 mm 1.776-39.770 31.Green Gray White. 39.5656 in.2499 in.802-39.5670 in.2512 1.771 mm 1.747 mm) OD inner race.5658-1.787-39.24981.807 mm 1.5652-1.754 mm) ID outer race and a 1. 1.5672 in. For example purposes.5672 in.792-39.2518 in.5662 in.2506 1.31.5652 in. (39.775 31.2504.Green Gray White.2516 1. 39.1.751-39. c.5648 in.5646-1.5654 in. 39.802 mm 1.765 31.2500 1.5660 in.741-39.5670-1. 31.751 mm 1.745 31. 31.5650 in.HOME NOTE Have machinist grind outer race to center or middle of required OD range. in.2514 1.5656-1.750 31.770 31. 31.5668 in.5648-1.746 mm Service Wear Limit Exceeded – Replace Outer Race and Resize Red Red Red Red Red Red Red Red Red Red Red Blue Blue WhiteGray Blue Blue Blue Blue Blue Blue Blue Blue Blue WhiteGray White. 39. suppose the largest inner race OD measurement after grinding is 1. a blue bearing is required.781-39-787 mm 1.5664-1. 31.792 mm 1. Check that speciﬁcations in Step 8 are met.761-39.760.5666-1.796 31. d.
Finger-tighten the sleeve parts. for use with tapered bearing. Tighten arbor expansion collars using a length of 0. If side play measurement is greater than service wear limit listed below. are assembled to case with bearings and small spacer collar. 2.030 in. If necessary. 3. ﬂush off lap in cleaning solvent. Secure right and left crankcase halves with three crankcase stud bolts (top center and bottom left and right).156 in. ● 0. The sprocket shaft bearing outer races and large spacer must be installed in left crankcase. smooth appearance. See Figure 3-126. Figure 3-126. Do not apply a heavy coat. Sleeves.” a condition where hole is larger at ends than it is in the center. Do not adjust arbor snug in bushing or bushing will “bell. HD96718-87) to lapping handle. Assemble guide sleeve to sprocket shaft bearing bushing. replace ﬂywheel/connecting rod assembly. Obtain CRANKCASE MAIN BEARING LAPPING TOOL (Part No. Lapping is completed when entire bushing surface has a dull. Lapping Pinion Shaft Main Bearing 7718 Crankcase Main Bearing Lapping Tool (Part No. HD-96710-40B). remove lap from crankcase. Reposition lap in bushing and turn handle at moderate hand speed. satin ﬁnish rather than a glossy. At frequent intervals. Check connecting rod side play with a thickness gauge as shown. (3. wash and inspect bushing. Insert lap shaft with arbor assembled through pinion bearing bushing and into guide sleeve.762 mm) Figure 3-127. to avoid grooving and tapering. 4.HOME Lapping Engine Main Bearing Races 1. a0094x3x Checking Connecting Rod Side Play 1. Assemble CRANKCASE MAIN BEARING LAP (Part No. See Figure 3-127.962 mm) rod as spanner until arbor begins to drag. Work lap back and forth in bushing. air dry and apply fresh. as it is revolved. HD-96710-40B) 2. (0. Withdraw arbor far enough to coat lightly with 220 grit lapping compound. Checking Connecting Rod Side Play 2002 Buell P3: Engine 3-71 . light coat of ﬁne lapping compound.
and proceed as follows: 1. b. Move snap ring if not properly centered. Verify that the gap in the snap ring is centered below the oil hole at the top of the ring groove. 3. Using a 9/64 inch allen head bit. a0095x3x f. With the gap in the snap ring being the 12 o’clock position. Retaining Ring Oil Supply Hole Oil Supply Channel d. compress the snap ring and install in groove of crankcase bore. Obtain the TIMKEN SNAP RING REMOVER/ INSTALLER (HD-44069). place the two claws so that the slotted sides engage the inside edge of the snap ring at the 10 and 2 o’clock positions.HOME ASSEMBLY 6151 3 2 Crankcase Halves Lubricate all parts with Harley-Davidson 20W50 engine oil. Place the crankcase half on a ﬂat surface with the outboard side facing up. a0096x3x HD-44069 Retaining Ring Remover/Installer Figure 3-128. 2. e. Install new snap ring to crankcase bore (if bearings were replaced). Snap Ring Installation 3-72 2002 Buell P3: Engine . g. Inserting the tips of a large retaining ring pliers (Snap-On PR-56A) into one hole in each claw. See Figure 3-128. Loosen allen head screws and remove claws from snap ring 1 1. a. c. tighten the screws to ﬁx the position of the claws on the snap ring.
Use SPROCKET SHAFT BEARING OUTER RACE INSTALLATION TOOL (Part No. Left Outer Race Bearing Installation 6. See Figure 3-129. 5. 8. Position right outer race over bearing bore on inboard side of left crankcase half. HD-42579) to install sprocket shaft tapered roller bearings and seal. Always install left outer race prior to installing right outer race because the installer base is usable only when you follow this sequence of race installation. 2. NOTE See Figure 3-129. d. Place new bearing. Insert shaft of installer plug through right outer race and into installer base. Press race into bore until ﬁrmly seated against retaining ring. 4. HD-39458) to install left and right outer races of sprocket shaft tapered roller bearings into left crankcase half. Right Outer Race Bearing Installation e. Rotate handle clockwise until bearing contacts ﬂywheel shoulder. Install Nice bearing. c. Figure 3-130. Install inner bearing. Insert shaft of installer plug through left outer race and into installer base. 2002 Buell P3: Engine 3-73 . small end upward. b. 7. 7711 7710 3. Slide sleeve over pilot until sleeve contacts inner bearing race. Figure 3-129. Sparingly apply graphite lubricant to threads of pilot shaft to ensure smooth operation. over end of sprocket shaft. Insert “SPORTSTER” end of installer base into inboard side of left crankcase half bearing bore until base contacts installed retaining ring. Use SPROCKET SHAFT BEARING/SEAL INSTALLATION TOOL (Part No.HOME NOTE See Figure 3-129. Press race into bore until ﬁrmly seated against retaining ring. See Figure 3-129. washer and handle on top of sleeve. a. Insert “SPORTSTER” end of installer base into outboard side of left crankcase half bearing bore until base contacts outboard surface of installed left outer race. Position left outer race over bearing bore on outboard side of left crankcase half. Remove tool from sprocket shaft. Thread pilot onto sprocket shaft until pilot bottoms on sprocket shaft shoulder.
c. Inner and outer bearings must be tight against inner spacer for correct bearing clearance. Center seal/spacer driver over seal. HD-42579) and SPROCKET SHAFT SEAL/SPACER INSTALLER (Part No. 1. 10. Install shim and outer bearing. so that the sleeve (smaller OD) seats between seal wall and garter spring. a. d. Place new outer bearing. a.HOME 9. Rotate handle clockwise until bearing ﬁrmly contacts inner spacer. See Figure 3-132. Install new spacer in seal ID. b. center seal/spacer assembly over bearing bore. Assemble Sprocket Shaft Bearing/Seal Installation Tool (Part No. 7663 2 1 3 5 4 6 e. See Figure 3-133. Installing Flywheel Spacer and Outer Bearing 3-74 2002 Buell P3: Engine . Remove tool from sprocket shaft. HD-42579) onto sprocket shaft. Do not remove the spacer after installation or the new seal will have to be discarded and the procedure repeated. HD42774) onto sprocket shaft. Follow procedure in Step 8. 6. f. 4. small end downward. See Figure 3-133. Carefully place crankcase half over sprocket shaft so that it rests ﬂat on inner bearing. 7666 c. With the open (lipped) side facing outward. Rotate handle clockwise until the spacer makes contact with the bearing. over sprocket shaft. 3. Assemble Sprocket Shaft Bearing/Seal Installation Tool (1) (Part No. Pilot Handle Washer Nice Bearing Sleeve Inner Bearing Figure 3-131. Slide new inner spacer over sprocket shaft until it contacts inner bearing race. Figure 3-132. Install bearing seal and spacer. Spin crankcase half to verify that ﬂywheel assembly is free. Remove tool from sprocket shaft. 5. 2. 11. Inner Bearing Installation b. Follow procedure in Step 8.
Place the end of the stud without the shoulder into the head screw. Slip bearing on pinion shaft. See 6. 23. f. 7662 Figure 3-134. 1. 4. Tighten the 5/1618 X 2-1/2 in fasteners to 15-19 ftlbs (20-26 Nm). 1. See 5. 19. a. HD-42579) Seal/Spacer Installer (Part No.5 CYLINDER HEAD. 16. 2. Tighten the 5/1618 X 3-1/2 in. Assemble crankcase halves together. 17. complete clutch assembly. Use a torque wrench to tighten stud to 10-20 ft-lbs (14-27 Nm). 2. Install transmission. See Figure 3-134. Cylinder Studs 2002 Buell P3: Engine 3-75 . Attach crankcase halves using hardware shown in Figure 3-115. b. c. See 3. This includes engine sprocket. Install primary cover. d. 3.4 ENGINE INSTALLATION and perform the applicable steps. 18. Install starter. The cylinder studs have a shoulder at the lower end. a.HOME 12.13 OIL PUMP. fasteners to 15-19 ftlbs (20-26 Nm).2 PRIMARY CHAIN. primary chain. lifter guides and lifters. Install piston and cylinder. See 3. Install cam gears. c. 24.6 PRIMARY DRIVE/CLUTCH. See 3. Place a steel ball into a head screw. Be sure to reﬁll transmission to proper level with fresh lubricant.16 GEARCASE COVER AND CAM GEARS. Install all primary drive components. See 6.6 CYLINDER AND PISTON. Remove air gun. a0120x3x d. See Figure 3-135. a. Install new retaining ring in groove of pinion shaft bearing inner race. Install shift linkage. Pack clean towels into crankcase opening. 20. Apply a thin coat of DOW CORNING SILASTIC or 3M 800 sealant to crankcase joint faces. c. Install the stud in the crankcase with the shoulder end down. HD-42774) Figure 3-133. Slide pinion shaft through outer race in right crankcase. b. fastener to 22-27 ft-lbs (30-37 Nm).14 TRANSMISSION INSTALLATION. Lubricate pinion shaft bearing with engine oil.10 TRANSMISSION/PRIMARY FLUID. Pinion Shaft Bearing 4 1 2 3 Head Screw with Ball Inside Cylinder Stud Shoulder on Cylinder Stud Air Gun Figure 3-135. Tighten 3/8-in. See 3. e. engine sprocket nut and mainshaft nut. NOTE See 1. Install Bearing Seal/Spacer 15. b. Install cylinder studs. Install pinion shaft bearing. 14. 7661 1 2 13. Install oil pump. Bearing/Seal Installer (Part No.7 STARTER. Install cylinder head. 21. See 6. 22. See 3. Use an air gun to drive the stud until the shoulder reaches the crankcase. gearcase cover. e.
HOME NOTES 3-76 2002 Buell P3: Engine .
This action might not be possible to undo. Are you sure you want to continue?
We've moved you to where you read on your other device.
Get the full title to continue listening from where you left off, or restart the preview.