buell s1 lightning '97 Manuel

 

1.

See 

 Using an arbor press, install pinion

shaft bushing (16) in its gearcase cover (17) so that
bushing is flush with cover boss. There is no need to ori-
ent this particular bushing in any specific position of rota-
tion within the gearcase cover bore.

2.

Although the original pinion shaft bushing is not “pinned,”
the replacement bushing must be secured, from possible
rotation within the cover bore, by installation of a dowel
pin. See 

 Drill a No. 31 hole, 0.281 in.

(7.14 mm) deep, at top side of boss (side toward top of
gearcase cover), centering the drill bit on the cover bore
circle (hole is drilled half in bushing OD and half in cover
bore ID).

3.

Drive a 

 

 dowel pin no more than 0.20 in. (5.1 mm)

below the bushing face. Carefully peen edges of hole to
lock the pin in place.

4.

After you install a 

 

 bushing in gearcase cover, line-

ream the bushing to the correct size. See 

.

 

NOTE

 

●

 

Installing and reaming crankcase and gearcase cover
bushings may alter the center distances between mating
gears and may result in an increase in gear noise. For
quiet-running gears, the gears should be matched to the
center distances.

 

●

 

Bushings in right crankcase half serve as pilots for ream-
ing gearcase cover bushings and must, therefore, be
reamed to size first.

 

●

 

After reaming any bushing, check shaft fit in the bushing.
It may be necessary to make a second pass with reamer
to attain proper fit.

 

1.

Separate two halves of crankcase, if not already accom-
plished. Place right crankcase half on flat surface with
gearcase side upward. Bushing to be reamed must be
oriented as shown in 

2.

See 

 Position 

 onto gearcase

side of crankcase half; upper right and lower left indexing
holes in pilot must be placed over dowels in crankcase
half. Insert two bolts (supplied with pilot) through two
remaining holes in pilot, and into threaded holes of
crankcase half. Tighten bolts securely.

3.

Insert the 11/16 in. diameter reamer through pilot hole
and into bushing while turning reamer clockwise. Con-
tinue turning reamer clockwise through bushing until
smooth shank of reamer passes through hole in pilot.

4.

Detach reamer from handle. Pull reamer out opposite
side of crankcase half.

5.

Thoroughly clean right crankcase half, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.

 

NOTE

Newly installed cam gear bushings in the gearcase cover
must be line reamed, using the right crankcase half as a pilot
for the reamer, to establish correct clearance and to ensure
perfect alignment. If crankcase halves are not separated on
your motorcycle, use a spare right crankcase half to perform
the following line reaming procedures.

 

1.

See 

must be installed in gearcase cover (17) as described in

. Attach gear-

case cover to right crankcase half (10), which has been
disassembled from left crankcase half, securing with a
minimum of three mounting screws.

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