Buell S1 Lightning Workshop Manual page 152

2771a
Figure 3-16. Checking Spring Free Length
5700
Gasket surface flat
within 0.006 in. (0.15 mm)
Figure 3-17. Checking Gasket Surface
Replacing Valve Guides
Valve guide replacement, if necessary, must be done before
valve seat is ground. It is the valve stem hole in valve guide
that determines seat grinding location. Valve stem-to-valve
guide clearances are listed in
guides are worn beyond service wear limits, install new parts.
Table 3-3. Valve Stem Clearances
and Service Wear Limits
VALVE CLEARANCE
Exhaust 0.0015-0.0033 in.
Intake 0.008-0.0026 in.
1. To remove shoulderless guides, press or tap guides
toward combustion chamber using
AND REMOVER (Part No.
2. Clean and measure valve guide bore in head.
3-16
Table 3-3. If valve stems and/or
SERVICE WEAR
LIMIT
0.0040 in.
0.0035 in.
DRIVER HANDLE
HD-34740).
2411a
9/16 in. -18 tap
Figure 3-18. Removing Rocker Arm Bushing
3. Measure outer diameter of a new standard valve guide.
The guide diameter should be 0.0020-0.0033 in. (0.051-
0.084 mm). larger than bore in head. If it is not, select
one of the following oversizes: +0.001 in., +0.002 in., or
+0.003 in. (+0.025, +0.05 +0.08 mm) (intake and
exhaust).
4. See Figure 3-19. Install shoulderless guides using
VALVE GUIDE INSTALLATION TOOL (Part No. HD-
34731) and DRIVER HANDLE (Part No.
Press or drive guide until the tool touches the machined
surface surrounding the guide. At this point, the correct
guide height has been reached.
5. Ream guides to final size or within 0.0010 in. (0.025 mm)
of final size using VALVE GUIDE REAMER (Steel, Part
No. HD-39932 or Carbide, Part No.
Use REAMER LUBRICANT (Part No. HD-39964)
eral amounts of suitable cutting oil to prevent reamer
chatter.
6. See Figure 3-20. Apply the proper surface finish to the
valve guide bores using the
No. HD-34723). Lubricate hone with honing oil. Driving
hone with an electric drill, work for a crosshatch pattern
with an angle of approximately 60°.
NOTE
The hone is not intended to remove material.
7. Thoroughly clean valve guide bores using
BRUSH (Part No. HD-34751)
HD-34740).
HD-39932-CAR).
or lib-
VALVE GUIDE HONE (Part
VALVE GUIDE
and hot soapy water.