buell s1 lightning '97 Manual

 

NOTE

The different sizes of crankcase sets and flywheel assemblies
will not have separate part numbers. That is, a replacement
crankcase set may have a class 1, 2 or 3 pinion outer race.
Replacement flywheel assemblies will have either a class A
or B inner race.

 

 Pinion bearings are identified as shown.

 

Select bearings using the identification information given for
inner and outer races and bearings. See 

 

NOTE

If either inner or outer race show wear, measure both races to
confirm correct bearing fit.

 

1.

Measure ID of outer race at four places with a dial bore
gauge. Take measurement on ID where bearing rollers
ride. Record the four measurements.

2.

If the largest measurement is larger than 1.5672 in.
(39.807 mm) or the required lapping to remove wear
marks would enlarge bore beyond 1.5672 in., continue at
Step 8.

3.

If the largest measurement is 1.5672 in. (39.807 mm) or
less, cover the cam bearings with masking tape to pre-
vent debris from entering bearings. Assemble crankcase
halves.

 

NOTE

The next step requires lapping the outer race. To keep
sprocket shaft and pinion shaft bearings aligned the lap must
be supported by an adaptor or pilot in the left crankcase half.

 

4.

See 

 on

. Race must be lapped until all wear marks are

removed.

5.

Measure ID of race at four places and record the mea-
surements.

6.

Check measurements against these specifications:

 

 1.5672 in. (39.807 mm) or less

 

 within 0.0002 in. (0.005 mm)

 

 within 0.0002 in. (0.005)

7.

If lapping increased bore ID to larger than 1.5672 in.
(39.807 mm), go to Step 8. If roundness or taper do not
meet specifications, continue lapping until specifications
are met. If all specifications are met, continue at Step 10
to remove and size inner race.

8.

Press the outer race from the right crankcase. Press 

 

outer race into crankcase flush with inside edge of cast-
in insert.

 Dimensions are shown for fabrication of

tools used in pressing the outer race into or out of crank-
case.

9.

The 

 

 outer race must be lapped slightly to true and

align with left case bearing and to meet the following
specifications. See 

.

 

 1.5646 - 1.5652 in. (39.741 - 39.756 mm)

 

 within 0.0002 in. (0.005 mm)

 

 within 0.0002 in. (0.005 mm)

 

 16 RMS

Largest

Smallest

Red

Blue

White (Grey)

Green

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