buell s1 lightning '97 Manual

9.

Check end play of rocker arm with feeler gauge.

10. Replace rocker arm or lower cover or both if end play

exceeds 0.025 in. (0.63 mm).

11. Valve heads should have a seating surface width of

0.040-0.062 in. (1.02-1.57 mm), and should be free of pit
marks and burn spots. The color of carbon on exhaust
valves should be black or dark brown. White or light buff
carbon indicates excessive heat and burning.

12. Valve seats are also subject to wear, pitting, and burning.

They should be resurfaced whenever valves are refin-
ished.

13. Clean valve guides by lightly honing with

14. Scrub guides with 

diameter and valve guide inner diameter. Check mea-
surements against 

.

15. Inspect spark plug threads for damage. If threads in head

are damaged, a special plug type insert can be installed
using a 12 mm spark plug repair kit.

16. Inspect valve springs for broken or discolored coils.

17. See 

 Check free length and compression

force of each spring. Compare with 

. If

spring length is shorter than specification, or if spring
compression force is below specification, replace spring.

18. Examine push rods, particularly the ball ends. Replace

any rods that are bent, worn, discolored, or broken.

19. See 

 Check head gasket surface on head for

flatness. Machine or replace any head which exceeds
SERVICE WEAR LIMIT of 0.006 in. (0.15 mm).

1.

See 

 To replace worn bushings, press or

drive them from the rocker arm. If bushing is difficult to
remove, turn a 9/16-18 tap into bushing. From opposite
side of rocker arm, press out bushing and tap.

2.

Press replacement bushing into rocker arm, flush with
arm end, and split portion of bushing towards top of arm.

3.

Using remaining old bushing as a pilot, line ream new
bushing with

4.

Repeat for other end of rocker arm.

2768a

5699

2770a