buell s1 lightning '97 Manual

 

5.

Check for minimum cam gear end play. See 

.

Record readings.

6.

Remove ignition system. See Section 7.

7.

Place a pan under gearcase to collect oil. Remove cover
screws. Carefully remove gearcase cover. Discard old
gasket (9).

 

NOTE

If cover does not come loose on removal of screws, tap lightly
with a plastic hammer. Never pry cover off.

 

8.

Remove cam gears (1, 2, 3 and 4). Carefully mark each
component to ensure correct installation.

 

NOTE

Nut (11) is secured by LOCTITE THREADLOCKER 262 (red)
on the nut threads.

 

9.

Remove nut (11). Slide pinion gear (5) and oil pump drive
gear (12) off pinion shaft.

 

1.

Thoroughly clean gearcase compartment, gearcase
cover, and gears in solvent to remove oil and carbon
deposits.

2.

Blow out all cover oil passages and bushings with com-
pressed air.

3.

Clean old gasket material from gearcase and cover faces
with cleaning solvent.

 

 Cam lobes are stamped with the number “15”

followed by a number (1, 2, 3 or 4). The number “15” indicates
model year application; the number identifies the cam location/
function:

15-1 = rear exhaust
15-2 = rear intake
15-3 = front intake
15-4 = front exhaust

Use only “15” cams on 1996 models.

ter over 0.108 in. (2.74 mm) diameter gauge pins on opposite
sides of the gear. The pins are of the proper size to fit
between the contacting surfaces of the gear teeth. Gear
diameter should be measured in at least two places 90

 

°

 

apart. Use

suring pinion and cam gear sizes.

Cam and pinion gears are individually selected for each spe-
cific gear cover through sophisticated computer-aided mea-
suring techniques in a controlled environment. Each gear is
assigned an individual color code based on its diameter
(measured with gauge pins). When cam and/or pinion gears
are replaced, always use the same color code as found on
gears being replaced to ensure that the gear operation
remains as quiet as possible. For location of cam and pinion
gear color codes, see 

 

NOTE

On flywheel pinion shaft, a paint dot is located on the shaft
perimeter near the centerline of the keyway. This dot identifies
the pinion shaft inner race size. Do not use this dot to select
pinion gear size.

 

 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.

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