Buell S1 Lightning Workshop Manual page 192

NOTE
The different sizes of crankcase sets and flywheel assemblies
will not have separate part numbers. That is, a replacement
crankcase set may have a class 1, 2 or 3 pinion outer race.
Replacement flywheel assemblies will have either a class A
or B inner race.
See Figure 3-78. Pinion bearings are identified as shown.
BEARING SELECTION
Select bearings using the identification information given for
inner and outer races and bearings. See
NOTE
If either inner or outer race show wear, measure both races to
confirm correct bearing fit.
1. Measure ID of outer race at four places with a dial bore
gauge. Take measurement on ID where bearing rollers
ride. Record the four measurements.
2. If the largest measurement is larger than 1.5672 in.
(39.807 mm) or the required lapping to remove wear
marks would enlarge bore beyond 1.5672 in., continue at
Step 8.
3. If the largest measurement is 1.5672 in. (39.807 mm) or
less, cover the cam bearings with masking tape to pre-
vent 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.
4. See LAPPING ENGINE MAIN BEARING RACES
page 3-58. Race must be lapped until all wear marks are
removed.
5. Measure ID of race at four places and record the mea-
surements.
6. Check measurements against these specifications:
Largest ID measured: 1.5672 in. (39.807 mm) or less
Roundness of ID: within 0.0002 in. (0.005 mm)
Taper: within 0.0002 in. (0.005)
7. If lapping increased bore ID to larger than 1.5672 in.
(39.807 mm), go to Step 8. If roundness or taper do not
meet specifications, continue lapping until specifications
are met. If all specifications are met, continue at Step 10
to remove and size inner race.
8. Press the outer race from the right crankcase. Press new
outer race into crankcase flush with inside edge of cast-
in insert.
See Figure 3-80. Dimensions are shown for fabrication of
tools used in pressing the outer race into or out of crank-
case.
9. The new outer race must be lapped slightly to true and
align with left case bearing and to meet the following
specifications. See LAPPING ENGINE MAIN BEARING
RACES on page 3-58.
ID: 1.5646 - 1.5652 in. (39.741 - 39.756 mm)
Roundness: within 0.0002 in. (0.005 mm)
Taper: within 0.0002 in. (0.005 mm)
Surface finish: 16 RMS
3-56
b0065x3x
Table 3-13.
b0165x3x
on
1.
2.
A – Roller OD cannot
be measured
to required accu-
racy with
micrometer
IDENTIFICATION
ROLLER OD (A)
Largest
Smallest
Figure 3-78. Bearing Identification
1.145 in.
(29.08 mm)
1.135 in.
(28.83 mm)
1
Pinion shaft inner race
Flywheel (gear side)
Figure 3-79. Inner Race Location
(Package color)
Red
Blue
White (Grey)
Green
2