Cylinder And Piston - Buell 2002 S3T Service Manual

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CYLINDER AND PISTON

REMOVAL/DISASSEMBLY
1. Strip motorcycle as described under
MOTORCYCLE FOR ENGINE
2. Remove cylinder head. See
3. Clean crankcase around cylinder base to prevent dirt
and debris from entering crankcase while removing cyl-
inder.
4. See Figure 3-29. Turn engine over until piston (3) of cyl-
inder being removed is at bottom of its stroke.
5. Carefully raise cylinder (1) just enough to permit placing
clean towel under piston to prevent any foreign matter
from falling into crankcase.
NOTE
If cylinder does not come loose, lightly tap a plastic hammer
perpendicular to the cylinder fins. Never try to pry a cylinder
up.
6. Carefully lift cylinder over piston and cylinder studs (4).
Do not allow piston to fall against cylinder studs. Discard
cylinder base gasket (5).
CAUTION
With cylinder removed, be careful not to bend the cylin-
der studs. The slightest bend could cause a stress riser
and lead to stud failure.
7. Install a 6.0 in. (152 mm) length of 1/2 in. (12.7 mm) ID
plastic or rubber hose over each cylinder stud. This will
protect the studs and the pistons.
11 1
WARNING
The piston pin retaining rings are highly compressed in
the ring groove and may "fly out" with considerable force
when pried out of the groove. Always wear safety
glasses or goggles while removing or installing retaining
rings. Failure to comply could result in death or serious
injury.
CAUTION
The piston pin retaining rings must not be reused.
Removal may weaken retaining rings and they may break
or dislodge. Either occurrence may damage engine.
8. Insert an awl in the recessed area below the piston pin
bore and pry out the piston pin retaining rings. To prevent
the ring from flying out, place your thumb over the retain-
ing ring.
NOTE
Since the piston pin is a loose fit in the piston, the pin will
easily slide out. The pins have tapered ends to help seat the
round retaining rings. See
are stamped with a V-groove at one end.
3-24 2002 Buell S3T: Engine
3.3 STRIPPING
REPAIR.
3.5 CYLINDER HEAD.
WARNING
Figure 3-30. 1203cc piston pins
b0056x3x
6
8
7
10
9
2
5
1. Cylinder
2. Dowel (2)
and O-Ring (2)
3. Piston
4. Cylinder Stud (4)
5. Base Gasket
Figure 3-29. Cylinder and Piston
3.6
7
3
1
4
6. Ring Set
7. Retaining Ring (2)
8. Piston Pin
9. Piston Pin Bushing
10. Connecting Rod