Buell S1 Lightning Workshop Manual page 184

GENERAL
When rod bearings, pinion shaft bearing or sprocket shaft
bearing are in need of repair, the engine must be removed
from the chassis. See REMOVING ENGINE CRANKCASE
OR COMPLETE ENGINE on
procedure to check and make repairs to cylinder heads, cylin-
ders, gearcase and transmission at the same time (perform
entire engine overhaul).
1
CAUTION
If engine is removed from chassis, do not lay engine on
primary side. Placing engine on primary side will damage
clutch cable end fitting. If fitting is damaged, clutch cable
must be replaced.
ADJUSTMENT/TESTING
Flywheel End Play
See Figure 3-64. Before completely disassembling crank-
cases, check flywheel end play.
3536a
Figure 3-64. Checking Flywheel End Play
1. After engine has been removed from chassis, securely
fasten it to a stand or workbench.
2. Remove gearcase cover. Attach a dial indicator to gear
side crankcase with indicator stem on end of gearshaft.
3. Sprocket shaft bearings must be preloaded to obtain an
accurate flywheel end play reading. A suitable tool can
be made by welding two handles to an old sprocket shaft
nut. Install the nut and sprocket. Tighten nut to 150-
165 ft-lbs (203-224 Nm).
3-48
CRANKCASE
page 3-8. It is recommended
4. Rotate and push on sprocket shaft while reading dial
indicator. Then rotate and pull on sprocket shaft while
reading dial indicator. If difference (end play) in indicator
readings is not 0.001-0.005 in. (0.025-0.13 mm), bearing
inner spacer (shim) (item 6,
replaced. Choose spacer from
spacer for less end play; use a thicker spacer for more
end play.
Table 3-11. Flywheel End Play
Spacers (Shims)
PART
NUMBER
IN.
9155 0.0975-0.0985
9142 0.0995 - 0.1005
9143 0.1015-0.1025
9144 0.1035 - 0.1045
9145 0.1055 - 0.1065
9146 0.1075 - 0.1085
9147 0.1095 - 0.1105
9148 0.1115 - 0.1125
9149 0.1135 - 0.1145
DISASSEMBLY
Crankcase Halves
1. Remove cylinder heads as described under
HEAD, REMOVAL on page
1
CAUTION
After removing cylinders, install plastic or rubber hose
over cylinder studs. Lifting or moving crankcase by
grasping studs will cause cylinder stud damage.
2. Remove cylinders and pistons. See
PISTON, REMOVAL/DISASSEMBLY
3. Remove oil pump as described under
REMOVAL/DISASSEMBLY
4. Remove gearcase components. See
COVER AND CAM GEARS, REMOVAL/DISASSEMBLY
on page 3-40.
5. Remove clutch and primary drive components. See
MARY DRIVE/CLUTCH in Section 6.
Figure 3-68.) must be
Table 3-11. Use a thinner
THICKNESS
MM
2.476-2.502
2.527-2.553
2.578-2.603
2.629-2.654
2.680-2.705
2.730-2.756
2.781-2.807
2.832-2.857
2.883-2.908
CYLINDER
3-11.
CYLINDER AND
on page 3-22.
OIL PUMP,
on page 3-35.
GEARCASE
PRI-