buell s1 lightning '97 Manual

 

1.

 Install oil pump drive gear (12) and pin-

ion gear (5) to pinion shaft. Note that timing mark on pin-
ion gear tooth is aligned with keyway in ID of pinion gear,
as shown in 

 The timing

mark will allow you to easily position pinion gear (1) over
shaft key (2) and against oil pump drive gear (3) on pin-
ion shaft (4).

2.

See 

 Clean pinion shaft threads and nut (11)

threads. Apply several drops of LOCTITE THREAD-
LOCKER 262 (red) to threads of nut. Install nut to pinion
shaft, tightening to 35-45 ft-lbs (47-61 Nm).

3.

. Liberally apply

engine oil to bushings, shafts, and gears. Install all cam
gears into bushings of right crankcase half, properly
aligning timing marks of cam gears and pinion gear as
shown in 

 

NOTE

Because of the larger diameter additional gear (which
meshes with the pinion gear) on the outboard end of the rear
intake (15-2) cam gear, the rear exhaust (15-1) and front
intake (15-3) cam gears must both be installed before the rear
intake (15-2) cam gear is installed.

 

4.

 Install a 

 

 seal (6) and 

 

 dry gas-

ket (9) on gearcase cover (17).

5.

Install gearcase cover over all gears and onto right
crankcase half (10). Secure cover to crankcase half with
11 socket head screws. Tighten screws evenly to 80-
110 

 

 (9.0-12.4 

Nm) according to the torque

sequence shown in 

6.

Check cam gear end play for each cam gear as follows:

a.  Turn engine over until lobe of cam gear being

checked is pointing toward its respective tappet
guide hole.

b.  Using a flat blade screwdriver, gently pry the cam

gear toward gearcase cover.

c.  Using a feeler gauge, measure gap between bush-

ing (in crankcase half) and cam gear shaft thrust
face (shoulder). This is cam gear end play.

d.  Compare your cam gear end play measurements

with the 

. Make

repairs as required if end gap is less than the mini-
mum specified, or greater than the maximum speci-
fied (Service Wear Limits).

3545a

b0178x3x

b0166x3x