Buell P3 2003 Service Manual page 222

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PINION SHAFT BUSHING IN GEARCASE COVER
1. See Figure 3-103. Using an arbor press, install pinion
shaft bushing in its gearcase cover so that bushing is
flush with cover boss. There is no need to orient this par-
ticular bushing in any specific position of rotation within
the gearcase cover bore.
2. See Figure 3-111. Although the original pinion shaft
bushing is not "pinned," the replacement bushing must
be secured from possible rotation within the cover bore
by installation of a dowel pin. Drill a No. 31 hole, 0.281 in.
(7.137 mm) deep, at top side of boss (side toward top of
gearcase cover), centering the drill bit on the cover bore
circle (hole is drilled half in bushing OD and half in cover
bore ID).
3. Drive a new dowel pin no more than 0.20 in. (5.08 mm)
below the bushing face. Carefully peen edges of hole to
lock the pin in place.
4. After you install a new bushing in gearcase cover, line-
ream the bushing to the correct size. See
Reaming.
7682
Figure 3-111. Drilling Dowel Pin Hole
Bushing Reaming
11 1
WARNING
Safety glasses or goggles must be worn while removing
metal chips/shavings. Failure to wear safety glasses or
goggles could result in death or serious injury.
NOTES
Installing and reaming crankcase and gearcase cover
bushings may alter the center distances between mating
gears and may result in an increase in gear noise. For
quiet-running gears, the gears should be matched to the
center distances.
Bushings in right crankcase half serve as pilots for ream-
ing gearcase cover bushings and must, therefore, be
reamed to size first.
After reaming any bushing, check shaft fit in the bushing.
It may be necessary to make a second pass with reamer
to attain proper fit.
3-68 2003 Buell P3: Engine
Bushing
WARNING
CAM GEAR BUSHINGS IN RIGHT CRANKCASE
HALF
1. Separate two halves of crankcase, if not already accom-
plished. Place right crankcase half on flat surface with
gearcase side upward. Bushing to be reamed must be
oriented as shown in Figure 3-108.
7739
Figure 3-112. Reaming Cam Gear Bushing in Right
Crankcase Half Using Camshaft Bushing Reamer
Pilot (Part No.B-43988)
2. See Figure 3-112. Position CAMSHAFT BUSHING
REAMER PILOT (Part No. B-43988) onto gearcase side
of crankcase half; upper right and lower left indexing
holes in pilot must be placed over dowels in crankcase
half. Insert two bolts (supplied with pilot) through two
remaining holes in pilot, and into threaded holes of
crankcase half. Tighten bolts securely.
3. Insert REAMER (Part No. HD-38871-2) through pilot
hole and into bushing while turning reamer clockwise.
Continue turning reamer clockwise through bushing until
smooth shank of reamer passes through hole in pilot.
4. Detach reamer from handle. Pull reamer out opposite
side of crankcase half.
11 1
WARNING
Low pressure compressed air can blow debris into your
face and eyes. Always wear eye protection or a face
shield when using pressurized air. Failure to take ade-
quate safety precautions could result in death or serious
injury.
5. Thoroughly clean right crankcase half, removing all
metal chips/shavings. Blow out all oil passages using
compressed air.
WARNING