Buell 2005 P3 Service Manual page 240

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Bushing Inspection
1. See Figure 3-103. Bushings are press fit in crankcase
and gearcase cover. Inspect each bushing against its
corresponding cam gear shaft or pinion gear shaft. See
Table 3-30.
NOTE
If Service Wear Limits are exceeded, replace crankcase set
and/or gearcase cover as required.
Table 3-30. Gear Shaft Specifications
GEAR CORRECT
SHAFT CLEARANCE
Cam 0.0007-0.0022 in.
(0.0178-0.0559 mm)
Pinion 0.0023-0.0043 in.
(0.0584-0.1092 mm)
ASSEMBLY/INSTALLATION
1. See Figure 3-107. Install oil pump drive gear (6) and pin-
ion gear (3) on pinion shaft (1).
a. Install shaft key (5) into pinion shaft slot.
b. Slide oil pump drive gear (6) over pinion shaft (1).
Drive gear must align with shaft key.
c. Align keyway (4) in ID of pinion gear with shaft key.
d. Slide pinion gear (3) over shaft key (5) and against
oil pump drive gear (6).
2. See Figure 3-108. Install nut.
a. Clean threads on pinion shaft and nut.
b. Install CRANKSHAFT LOCKING TOOL (Part No.
HD-43984) to gearcase with "Side B" facing out,
over pinion shaft, with two screws.
c. Apply several drops of LOCTITE 262 (red) to last
few threads of nut.
d. Install nut to pinion shaft. Tighten nut to 19-21 ft-lbs
(26-29 Nm) plus an additional 15˚ to 17˚ rotation.
3. See Figure 3-103. Liberally apply engine oil to bushings,
shafts, and gears. Install all cam gears into bushings of
right crankcase half, properly aligning timing marks of
cam gears and pinion gear.
NOTE
Because of the larger diameter additional gear (which
meshes with the pinion gear) on the outboard end of the cam,
the exhaust cam gear must be installed before the intake cam
gear is installed.
4. See Figure 3-103. Install a new seal and new dry gear
cover gasket on crankcase.
3-66 2005 Buell P3: Engine
a0078x3x
SERVICE WEAR
LIMIT
0.003 in.
1.
(0.076 mm)
2.
0.0050 in.
3.
(0.1270 mm)
4.
5.
6.
7686
1
2
3
4
5
6
Pinion shaft
Timing mark on pinion gear
Pinion gear
Keyway
Shaft key
Oil pump drive gear
Figure 3-107. Aligning Pinion Gear
Figure 3-108. Crankshaft Locking Tool (HD-43984)