buell s1 lightning '97 Manual

 

1.

See 

 Bushings (7, 8, 13, 14, 15 and 16) are

press fit in gearcase cover (17) and crankcase. Inspect
each bushing against its corresponding cam gear shaft
or pinion gear shaft. See 

2.

See 

 to remove bushings

from gearcase cover and crankcase.

 

NOTE

Installing and reaming crankcase and gearcase cover bush-
ings 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.

 

1.

See 

 Each cam gear bushing (1), to be

installed in right crankcase half (2), must be positioned in
crankcase bore with its oiling slot at exact top of bore (12
o’clock position).

2.

Using an arbor press, install each bushing in its crank-
case bore so that bushing shoulder contacts crankcase
boss.

3.

After you install a 

 

 bushing in right crankcase half,

ream the bushing to correct size. See 

.

 

1.

 Using an arbor press, install each bush-

ing (7, 8 and 14) in its gearcase cover (17) bore so that
bushing shoulder contacts cover boss. There is no need
to orient these particular bushings in any specific position
of rotation within gearcase cover bores.

2.

After you install a 

 

 bushing in gearcase cover, line-

ream the bushing to correct size. See 

.

 

.

 

1.

See 

 Rear intake cam gear bushing (15)

must be installed in its gearcase cover (17) bore using an
arbor press. You will need to orient the bushing in a spe-
cific position of rotation within the cover bore, and will
need to drill a lubrication hole in the bushing, according
to the following procedures

2.

See 

 Position bushing (1) over bore of gear-

case cover (2) with chamfered edge downward and slot
upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
with cover boss.

3.

Drill a 5/32 in. (3.97 mm) diameter hole through bushing
using existing hole in gearcase cover as a guide.

4.

After you install a 

 

 bushing in gearcase cover, line-

ream the bushing to the correct size. See 

.

 

Cam

0.0007-0.0022 in.

(0.018-0.056 mm)

0.003 in.

(0.08 mm)

Pinion

0.0023-0.0043 in.

(0.058-0.109 mm)

0.005

(0.13 mm)

2806a

xlh0355