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buell s1 lightning '97 Manual

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3-24
 
Measuring Cylinder Bore 
 
1.
Remove any burrs from the cylinder gasket surfaces.
2.
See 
Figure 3-30.
 Install a head and base gasket, and
CYLINDER TORQUE PLATES (Part No. HD-33446A)
and 
TORQUE PLATE BOLTS (Part No. HD-33446-86).
Tighten the bolts using the same method used when
installing the cylinder head screws. See 
CYLINDER
HEAD, INSTALLATION 
on 
page 3-20
.
 
NOTE
Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will vary
as much as 0.001 in. (0.025 mm) without torque plates.
 
3.
Take cylinder bore measurement in ring path, starting
about 1/2 in. (13 mm) from top of cylinder, measuring
from front to rear and then side to side. Record readings.
4.
Repeat measurement at center and then at bottom of
ring path. Record readings. This process will determine if
cylinder is out-of-round (or “egged”) and will also show
any cylinder taper or bulge. 
5.
See 
 If cylinder is not scuffed or scored and is
.
 
NOTE
If piston clearance exceeds service limit, cylinders should be
rebored and/or honed to next standard oversize, and refitted
with the corresponding piston and rings. Do not fit piston
tighter than 0.0007 in. (0.018 mm) See 
SPECIFICATIONS
.
 
Figure 3-29. Checking Gasket Surfaces
2781a
Gasket surface flat within
0.006 in. (0.15 mm)
 
Figure 3-30. Measuring Cylinder Bore Using Torque 
Plates (Part No. HD-33446A)
 
Table 3-6. 1200cc Cylinder Bore 
Service Wear Limits 
 
BORE SIZES
IN.
MM
 
Standard Bore
3.5008
88.920
0.005 in. OS bore
(0.13 mm)
3.5050
89.027
0.010 in. OS bore
(0.25 mm)
3.5100
89.154
0.020 in. OS bore
(0.51 mm)
3.5200
89.408
0.030 in. OS bore
(0.76 mm)
3.5300
89.662
2782a