buell s1 lightning '97 Manual
3-27
REPAIR
1
CAUTION
Replace bent connecting rods. Do not attempt to
straighten. Straightening rods by bending will damage
the bearing on the crank pin and the piston pin bushing.
Installing bent connecting rods will damage cylinder and
piston beyond repair.
straighten. Straightening rods by bending will damage
the bearing on the crank pin and the piston pin bushing.
Installing bent connecting rods will damage cylinder and
piston beyond repair.
ASSEMBLY/INSTALLATION
1.
Install piston assembly over connecting rod.
NOTE
New 1200cc pistons must be installed with the arrow, at the
top of the piston, pointing towards the front of the engine.
top of the piston, pointing towards the front of the engine.
2.
Install piston pin.
1
CAUTION
Always use new retaining ring. Make sure retaining ring
groove is clean and that ring seats firmly in groove. If it
does not, discard the ring. Never install a used retaining
ring or a new one if it has been installed and then
removed for any reason. A loosely installed ring will
come out of the piston groove and damage cylinder and
piston beyond repair.
groove is clean and that ring seats firmly in groove. If it
does not, discard the ring. Never install a used retaining
ring or a new one if it has been installed and then
removed for any reason. A loosely installed ring will
come out of the piston groove and damage cylinder and
piston beyond repair.
3.
Install
new
piston pin retaining rings with the
PISTON
PIN RETAINING RING INSTALLER (Part No. HD-34623A)
. Make sure the ring groove is clean and that the
ring is fully seated in the groove with the gap away from
the slot at the bottom.
the slot at the bottom.
4.
Make sure the piston ring end gaps are
properly positioned as shown.
5.
Lubricate cylinder wall, piston, pin and rod bushing with
engine oil.
engine oil.
6.
Turn engine until piston is at top dead center.
7.
Compress the piston rings using
PISTON RING COM-
PRESSOR (Part No. HD-96333-51B)
.
8.
Remove cylinder stud sleeves. Install a
new
cylinder
base gasket. Make sure the piston does not bump the
studs or crankcase.
studs or crankcase.
9.
Install cylinder over piston.
10. Remove piston ring compressor.
11. Assemble and install cylinder head. See
CYLINDER
HEAD, ASSEMBLY
starting on
page 3-19
.
12. Install assembled engine. See
INSTALLING THE
ENGINE
on
page 3-10
.
Figure 3-36. Piston Pin Bushing Tool Assembly for Bushing Removal
1.
Receiver cup
2.
Driver
3.
Washer
4.
Nut
5.
Bolt
b0173x3x
5
3
4
1
2
Figure 3-37. Installing New Piston Pin Bushing
2786a
Piston Pin Bushing Tool
(Part No. HD-95970-32C)
(Part No. HD-95970-32C)
Rod Clamping Fixture
(Part No. HD-95952-33A)
(Part No. HD-95952-33A)