Crankcase - Buell 2002 P3 Service Manual

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CRANKCASE

GENERAL
If engine is removed from chassis, do not lay engine on
primary side. Placing engine on primary side will dam-
age clutch cable end fitting. If fitting is damaged, clutch
cable must be replaced.
See 3.3 STRIPPING MOTORCYCLE FOR ENGINE REPAIR/
REMOVAL. Remove engine from chassis to repair pinion
shaft bearing or sprocket shaft bearing.
It is recommended procedure to overhaul engine if removed.
This includes inspecting and repairing cylinder head, cylinder,
gearcase and transmission.
ADJUSTMENT/TESTING
Flywheel End Play
Before completely disassembling crankcases, check flywheel
end play.
1. After engine has been removed from chassis, securely
fasten it to a stand or workbench.
2. See 3.16 GEARCASE COVER AND CAM
Remove gearcase cover.
3. See Figure 3-114. Attach a dial indicator to gear side
crankcase with indicator stem on end of gearshaft.
4. To obtain an accurate flywheel end play reading, preload
sprocket shaft bearings. Create a suitable tool by weld-
ing two handles to an old engine sprocket nut. Install the
nut and sprocket. Tighten to 190-210 ft-lbs (258-
285 Nm).
5. Check flywheel end play.
a. Rotate and push on sprocket shaft while reading
dial indicator.
b. Then rotate and pull on sprocket shaft while reading
dial indicator.
c. Replace bearing inner shim if difference (end play)
in indicator readings is not 0.001-0.005 in. (0.025-
0.127 mm). Choose shim from
NOTE
Use a thinner shim for less end play; use a thicker shim for
more end play.
3-64 2002 Buell P3: Engine
a0135x3x
GEARS.
9155
9142
9143
9144
9145
9146
9147
9148
9149
Table 3-14.
Figure 3-114. Checking Flywheel End Play
Table 3-14. Flywheel End Play Shims
PART
NUMBER
IN.
0.0975-0.0985
0.0995 - 0.1005
0.1015-0.1025
0.1035 - 0.1045
0.1055 - 0.1065
0.1075 - 0.1085
0.1095 - 0.1105
0.1115 - 0.1125
0.1135 - 0.1145
3.17
THICKNESS
MM
2.4765-2.5019
2.5273-2.5527
2.5781-2.6035
2.6289-2.6543
2.6797-2.7051
2.7305-2.7559
2.7813-2.8067
2.8321-2.8575
2.8829-2.9083