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buell s1 lightning '97 Manual

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3-2
 
ITEM
NEW COMPONENTS
SERVICE WEAR LIMITS
ROCKER ARM
 
Shaft fit in bushing (loose)
0.0005-0.0020 in.
0.013-0.051 mm
0.0035 in.
0.089 mm
End clearance
0.003-0.013 in.
0.08-0.33 mm
0.025 in
0.64 mm
Bushing fit in rocker arm (tight)
0.004-0.002 in.
0.10-0.05 mm
 
ROCKER ARM SHAFT
 
Shaft fit in rocker cover (loose)
0.0007-0.0022 in.
0.018-0.056 mm
0.0035 in.
0.089 mm
 
PISTON
 
Compression ring gap 
(top and 2nd)
0.007-0.020 in.
0.18-0.51 mm
0.032 in.
0.81 mm
Oil control ring rail gap
0.009-0.052 in.
0.23-1.32 mm
0.065 in
1.65 mm
Compression 
ring side
clearance
Top
0.0020-0.0045 in.
0.051-0.114 mm
0.0065 in.
0.165 mm
2nd
0.0016-0.0041 in.
0.041-0.104 mm
0.0065 in.
0.165 mm
Oil control ring side clearance
0.0016-0.0076 in.
0.041-0.193 mm
0.0094 in.
0.239 mm
Pin fit 
(loose, at room temperature)
0.00005-0.00045 in.
0.0013-0.0114 mm
0.00100 in.
0.0254 mm
 
CYLINDER HEAD
 
Valve guide in head (tight)
0.0033-0.0020 in.
0.084-0.051 mm
Valve seat in head (tight)
0.0035-0.0010 in.
0.089-0.025 mm
Head gasket surface (flatness)
0.006 in. total
0.15 mm total
0.006 in. total
0.15 mm total
 
CYLINDER
 
Taper
0.002 in.
0.05 mm
Out of round
0.003 in.
0.08 mm
Warpage 
(gasket surfaces)
Top
0.006 in.
0.15 mm
Base
0.008 in.
0.20 mm
Bore diameter
 
±
 
 0.0002 in.
OS=over size
Standard
3.4978 in.
88.844 mm
3.5008 in.
88.920 mm
0.005 OS
3.502 in.
88.95 mm
3.505 in.
89.03 mm
0.010 OS
3.507 in.
89.08 mm
3.510 in.
89.15 mm
0.020 OS
3.517 in.
89.33 mm
3.520 in.
89.41 mm
0.030 OS
3.527 in.
89.59 mm
3.530 in.
89.66 mm
 
CONNECTING ROD
 
Piston pin fit (loose)
0.00125-0.00175 in.
0.0318-0.0445 mm
0.00200 in.
0.0508 mm
Side play between flywheels
0.005-0.025 in.
0.13-0.64 mm
0.030 in.
0.76 mm
Fit on crankpin (loose)
0.0004-0.0017 in.
0.010-0.043 mm
0.0027 in.
0.069 mm
 
TAPPET
 
Fit in guide
0.0008-0.0023 in.
0.020-0.058 mm
0.003 in.
0.08 mm
Roller fit
0.0006-0.0013 in.
0.015-0.033 mm
Roller end clearance
0.008-0.022 in.
0.203-0.599 mm
0.026 in.
0.660 mm
 
OIL PUMP
 
Oil pressure at 
normal operating 
temperature
1000 RPM
7-12 PSI
0.5-0.8 kN/cm
 
2
 
2500 RPM
10-17 PSI
0.7-1.2 kN/cm
 
2
 
Shaft to pump clearance
0.0025 in.
0.064 mm
Feed/scavenge inner/outer
gerotor clearance
0.003 in.
0.08 mm
0.004 in.
0.10 mm