Buell S1 Lightning Workshop Manual page 162

2783a
Figure 3-32. Measuring Ring End Gap
2784a
Apply engine oil to piston
grooves to aid ring installation
Transmission Shaft Retaining
Ring Pliers (Part No. J-5586)
Figure 3-33. Installing Piston Rings
Connecting Rod Bushing
REMOVAL/INSTALLATION
When connecting rod bushing is worn to excessive pin clear-
ance (0.002 in. or more) (0.05 mm) it must be replaced.
1. See Figure 3-37. Install plastic hoses over studs.
2. Secure connecting rod with
CLAMPING TOOL (Part No.
NOTE
If CONNECTING ROD CLAMPING TOOL holes are too
small, enlarge the holes in the tool.
3. See Figure 3-36. Attach
(Part No. HD-95970-32C)
cup on one side of the rod and the driver on the opposite
side) as shown.
3-26
CONNECTING ROD
HD-95952-33A).
PISTON PIN BUSHING TOOL
to the connecting rod (receiver
b0095x3x
Position ring end gaps at arrows–
minimum of 90° apart
FRONT
Piston
REAR
Figure 3-34. Ring End Gap Position
2785a
Figure 3-35. Measuring Ring Clearance in Groove
4. Use two box wrenches and push worn bushing from con-
necting rod.
5. Remove piston pin bushing tool from connecting rod.
6. Remove bushing from receiver cup.
7. See Figure 3-37. Attach
(Part No. HD-95970-32C)
bushing between connecting rod and driver.
NOTE
The driver must be attached facing the opposite direction as it
was for removal of the bushing.
8. Clean up and size bushing to 0.0010-0.0005 in.
(0.025-0.013 mm) undersize using
HD-94800-26A). Sizing bushing with less than 0.00125
in. (0.0317 mm) clearance can result in a bushing loos-
ening and/or seized pin in rod.
9. Hone bushing to final size using
HONE (Part No. HD-35102). Use a liberal amount of
honing oil to prevent damage to hone or bushing. Use
care to prevent foreign material from falling into the
crankcase.
pin
PISTON PIN BUSHING TOOL
to connecting rod; place new
REAMER (Part No.
WRIST PIN BUSHING