Buell S1 Lightning Workshop Manual page 172

CLEANING, INSPECTION
AND REPAIR
1. Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.
2. See Figure 3-47. Inspect both gerotor sets for wear.
Mesh pieces of each set together as shown. Use a feeler
gauge to determine clearance.
NOTE
The maximum allowable clearance between gerotors is
0.004 in. (0.10 mm). Replace gerotors as a set if clearance
exceeds this dimension.
3. Measure thickness of feed gerotors with a micrometer. If
they are not the same thickness, replace as a set.
4. Check gear shaft (11) teeth for damage or wear. Replace
if necessary.
ASSEMBLY/INSTALLATION
1. See Figure 3-46. Install gear shaft (11) through body
(12). Position thrust washer (15) over end of shaft. Install
new retaining ring (16) into groove in shaft.
NOTE
Liberally coat all moving parts with clean engine oil to ensure
easy assembly and smooth operation at start-up.
2. Insert inner gerotor of the scavenge gerotor set (9) over
gear shaft.
3. Place outer gerotor over inner to complete scavenge
set (9).
4. Position separator plate (8) into case and line up slots on
perimeter with tabs inside oil pump body (12).
5. Place feed gerotor set (7) over gear shaft (11).
6. Install a new O-ring (14) into groove in cover (6). Place
cover onto pump body. Install cover screws (2) with
washers (3). Tighten cover screws (2) to 125-150 in-lbs
(14.1-16.9 Nm).
3-36
b0097x3x
Inner gerotor
Outer gerotor
Figure 3-47. Gerotor Wear Limits
7. Place new mounting gasket (10) in position.
8. See Figure 3-45. Attach return hose (4) to oil pump.
9. Secure pump to crankcase with screws (1) and washers.
Tighten mounting screws to 125-150 in-lbs (14.1-
16.9 Nm).
10. Connect feed hose (3) and oil filter mount connection (5)
to oil pump.
NOTE
Use new hose clamps. If fittings were removed, use
TEFLON® PIPE SEALANT or HYLOMAR® on fitting threads.
11. Attach clamp (6) and canister to oil hose.
12. Prime oil pump. Loosen feed hose connection and start
engine. Operate at idle and allow about 2.0 ounces
(0.06 liter) of engine oil to be forced through hose con-
nection. Stop engine and tighten hose connection.
13. Check engine oil level in tank. Add oil to correct level if
needed. See ENGINE LUBRICATION SYSTEM
tion 1.
Wear limit
in Sec-