Buell 2002 P3 Service Manual page 149

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ROCKER ARM
Shaft fit in bushing (loose)
End clearance
Bushing fit in rocker arm (tight)
Rocker arm shaft fit in
rocker cover (loose)
PISTON
Compression ring gap
(top and 2nd)
Oil control ring rail gap
Compression Top
ring side
2nd
clearance
Oil control ring side clearance
Pin fit
(loose, at room temperature)
CYLINDER HEAD
Valve guide in head (tight)
Valve seat in head (tight)
Head gasket surface (flatness)
CYLINDER
Taper
Out of round
Warpage Top
(gasket surfaces)
Base
Bore diameter Standard
± 0.0002 in.
0.005 OS
0.010 OS
OS=over size
0.020 OS
0.030 OS
CONNECTING ROD
Piston pin fit (loose)
Side play between flywheels
Fit on crankpin (loose)
Connecting rod race ID
3-2 2002 Buell P3: Engine
NEW COMPONENTS
0.0005-0.0020 in. 0.0127-0.0508 mm
0.003-0.013 in. 0.076-0.330 mm
0.004-0.002 in. 0.102-0.0559 mm
0.0007-0.0022 in. 0.018-0.056 mm
NEW COMPONENTS
0.007-0.020 in. 0.178-0.508 mm
0.009-0.052 in. 0.229-1.321 mm
0.0020-0.0045 in. 0.0508-0.1143 mm
0.0016-0.0041 in. 0.0406-0.1041 mm
0.0016-0.0076 in. 0.0406-0.1930 mm
0.00127-0.01143
0.00005-0.00045 in.
NEW COMPONENTS
0.0033-0.0020 in. 0.0838-0.0508 mm
0.0035-0.0010 in. 0.0889-0.0254 mm
0.006 in. total 0.152 mm total
NEW COMPONENTS
3.4978 in. 88.8441 mm
3.502 in. 88.951 mm
3.507 in. 89.078 mm
3.517 in. 89.332 mm
3.527 in. 89.586 mm
NEW COMPONENTS
0.03175-0.04445
0.00125-0.00175 in.
0.005-0.025 in. 0.127-0.635 mm
0.0004-0.0017 in. 0.0102-0.0432 mm
41.2623-41.2750
1.6245-1.6250 in.
SERVICE WEAR LIMITS
0.0035 in.
0.025 in
0.0035 in.
SERVICE WEAR LIMITS
0.032 in.
0.065 in
0.0065 in.
0.0065 in.
0.0094 in.
0.00100 in.
mm
SERVICE WEAR LIMITS
0.006 in. total
SERVICE WEAR LIMITS
0.002 in.
0.003 in.
0.006 in.
0.008 in.
3.5008 in.
3.5050 in.
3.5100 in.
3.5200 in.
3.5300 in.
SERVICE WEAR LIMITS
0.00200 in.
mm
0.030 in.
0.0027 in.
1.6270 in.
mm
0.0889 mm
0.635 mm
0.0889 mm
0.813 mm
1.651 mm
0.1651 mm
0.1651 mm
0.2388 mm
0.02540 mm
0.152 mm total
0.051 mm
0.076 mm
0.152 mm
0.203 mm
88.9203 mm
89.0270 mm
89.1540 mm
89.4080 mm
89.6620 mm
0.05080 mm
0.762 mm
0.0686 mm
41.3258 mm