Buell P3 2003 Service Manual page 223

HOME
EXHAUST GEAR BUSHING IN GEARCASE COVER
NOTE
Newly installed cam gear bushings in the gearcase cover
must be line reamed, using the right crankcase half as a pilot
for the reamer, to establish correct clearance and to ensure
perfect alignment. If crankcase halves are not separated on
your motorcycle, use a spare right crankcase half to perform
the following line reaming procedures.
1. See Figure 3-103. Bushings to be reamed must be
installed in gearcase cover as described in
INSTALLATION. Attach gearcase cover to right crank-
case half, which has been disassembled from left crank-
case half, securing with a minimum of three mounting
screws.
2. Insert REAMER (Part No. HD-38871-2) through the pre-
viously reamed cam gear bushing in right crankcase half,
which is in line with exhaust bushing to be reamed in
gearcase cover.
3. Turn reamer clockwise through bushing in cover until
reamer bottoms. Then give reamer one complete clock-
wise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.
4. Separate gearcase cover from right crankcase half.
Inspect bushings for proper cam gear shaft fit. Repeat
line reaming operation if necessary.
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 gearcase cover, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.
INTAKE CAM GEAR BUSHING IN
GEARCASE COVER
NOTE
A newly installed intake cam gear bushing in the gearcase
cover must be line reamed, using the right crankcase half as
a pilot for the reamer, to establish correct clearance and to
ensure perfect alignment. If crankcase halves are not sepa-
rated on your motorcycle, use a spare right crankcase half to
perform the following line reaming procedures.
1. See Figure 3-103. Intake cam gear bushing must be
installed in gearcase cover as described in
Installation.
BUSHING
WARNING
Bushing
7715
1
1
3
1. Reamer (Part No. HD-94804-67)
2. RIght crankcase half
3. Gearcase cover
4. Intake cam bushing
Figure 3-113. Line Reaming Intake Camshaft Bushing
2. See Figure 3-113. Identify the previously reamed intake
cam gear bushing in right crankcase half, which has
been disassembled from left crankcase half. Insert the
shank end of INTAKE CAMSHAFT BUSHING REAMER
(Part No. HD-94804-67) through gearcase side of this
bushing.
3. With reamer inserted into bushing in right crankcase half,
attach gearcase cover to right crankcase half, securing
with a minimum of three mounting screws.
4. Turn reamer clockwise through bushing in gearcase
cover until reamer bottoms. Then give reamer one com-
plete clockwise turn to size the bushing. Continue turning
reamer clockwise while extracting reamer from bushing.
5. Separate gearcase cover from right crankcase half.
Inspect bushing for proper cam gear shaft fit. Repeat line
reaming operation if necessary.
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.
6. Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.
4
WARNING
2003 Buell P3: Engine 3-69