Buell 2005 P3 Service Manual page 247

HOME
1. Use a dial bore gauge to measure and record ID of outer
race. Take four measurements on ID where bearing roll-
ers ride.
a. If the largest measurement is larger than 1.5672 in.
(39.8069 mm) or the required lapping to remove
wear marks would enlarge bore beyond 1.5672 in.,
continue at Step 5.
b. If largest measurement is 1.5672 in. (39.8069 mm)
or less, cover the cam bearings with masking tape to
prevent debris from entering bearings. Assemble
crankcase halves.
NOTE
The next step requires lapping the outer race. To keep
sprocket shaft and pinion shaft bearings aligned the lap must
be supported by an adaptor or pilot in the left crankcase half.
2. See LAPPING ENGINE MAIN BEARING RACES.
race until all wear marks are removed.
3. Measure and record ID of race at four places.
4. Check measurements against these specifications in
Table 3-35. Outer Pinion Race Service Wear
a. If lapping increased bore ID to larger than 1.5672 in.
(39.8069 mm), go to Step 5.
b. If roundness or taper do not meet specifications,
continue lapping until specifications are met.
c. If all specifications are met, continue at Step 7 to
remove and size inner race.
5. Press the outer race from the right crankcase. Press
new outer race into crankcase flush with inside edge of
cast-in insert.
See Figure 3-121. Dimensions are shown for fabrication
of tools used in pressing the outer race into or out of
crankcase.
6. See LAPPING ENGINE MAIN BEARING RACES.
new outer race must be lapped slightly to true and align
with left case bearing and to meet the following specifica-
tions.
Table 3-35. Outer Pinion Race Service
Largest ID measured
Roundness of ID
Taper
a0109x3x
Lap
5/16"
(7.94 mm)
DRILL
Limits.
5/16"
(7.94 mm)
DRILL
1.50" (38.1 mm)
(25.4 mm)
The
1.272" (32.31 mm)
1.262" (32.05 mm)
Figure 3-121. Pinion Shaft Bearing Tools
Wear Limits
in.
1.5672
within 0.0002
within 0.0002
Pinion outer race
installation
2.00"
(50.8 mm)
.187" (4.75 mm)
1.00
(25.4 mm)
Pinion outer race
1.560"
(39.62 mm)
removal
.187" (4.75 mm)
1.00
(25.4 mm)
1.560"
(39.62 mm)
Pinion inner race
installation
1.00"
5.50" (139.7 mm)
1.145" (29.08 mm)
1.135" (28.83 mm)
2005 Buell P3: Engine
mm
39.8
0.0051
0.0051
3-73