buell s1 lightning '97 Manual

 

2.

Compare the measurements recorded in Step 1 with the
ranges given in 

 If the four measurements

taken in each race differ, use the smallest measure-
ments.

 

NOTE

Front and rear rod race ID must be within the same tolerance
range given in the above table. The following example will
illustrate the procedure necessary if the lapped connecting
rod races on both rods do not fall in the same range.

 

3.

As an example, assign the following values to the mea-
surements taken in Step 1.

Front connecting rod race diameter: 1.6255 in.

(41.288 mm)

Rear connecting rod race diameter: 1.6250 in.

(41.275 mm)

See 

 For the above example measurements, the

front connecting rod would require a 0.0010 in. (0.025 mm)
oversize crank pin, while the rear connecting rod could use
the standard sized crank pin. The rear connecting rod races
must be lapped so they have the same ID (within 0.0002 in.
(0.005 mm)) as the front rod.

4.

See 

 Oversize (OS) crank pins are available

in two oversizes: 0.0010 and 0.0020 in. (0.025 and 0.051
mm) OS crank pins will have a blue or red paint dot
applied to the ends of the pins. A blue dot indicates
0.0010 in. (0.025 mm) OS, a red dot indicates 0.0020 in.
(0.051 mm) OS. Standard size crank pins will not be
marked.

5.

Before assembling the flywheel assembly, recheck con-
necting rods as follows:

1

 

Rear . . . . . . . . . . . . . . Difference in ID of two races must not

exceed 0.0001 in. (0.0025 mm).

Front and rear  . . . . . . Difference  in  ID  of  races  in  front  and

rear connecting rods must not exceed
0.0002 in. (0.005 mm).

Front and rear  . . . . . . Races 

must 

be 

round 

within

0.00025 in.  (0.0064 mm).  (Difference
between largest and smallest ID mea-
surement in any race must not exceed
0.00025 in. (0.0064 mm)).

 

NOTE

Always use 

 

 bearings and crank pin after resizing (lap-

ping) connecting rods to insure proper running clearance.

1

 

If flywheel end play is within tolerance, and if tapered roller
bearings and races pass visual check and have no apparent
wear, the same set may be reinstalled. Make certain all parts
of bearing are installed in exactly the same order in which
they were removed. If any part of bearing assembly is worn,
entire assembly should be replaced.

 

See 

 A pressed-in bushing in the right crankcase

half is the outer race (13). The inner race (12) is pressed on
the pinion shaft.

1.6245-1.6250 in.
(41.262-41.275 mm)

Standard

1.6255-1.6260 in.
(41.288-41.300 mm)

0.0010 in. oversize (0.025 mm)

1.6265-1.6270 in.
(41.313-41.326 mm)

0.0020 in. oversize (0.051 mm)

Greater than 1.6270 in.
(41.326 mm)

Service Wear Limit exceeded.
Replace races or connecting rod
set.

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