Buell S1 Lightning 1996 Manual page 108

ITEM
ROCKER ARM
Shaft fit in bushing (loose)
End clearance
Bushing fit in rocker arm (tight)
ROCKER ARM SHAFT
Shaft fit in rocker cover (loose)
PISTON
Compression ring gap
(top and 2nd)
Oil control ring rail gap
Compression Top
ring side
2nd
clearance
Oil control ring side clearance
Pin fit
(loose, at room temperature)
CYLINDER HEAD
Valve guide in head (tight)
Valve seat in head (tight)
Head gasket surface (flatness)
CYLINDER
Taper
Out of round
Warpage Top
(gasket surfaces)
Base
Bore diameter Standard
0.0002 in.
0.005 OS
0.010 OS
OS=over size
0.020 OS
0.030 OS
CONNECTING ROD
Piston pin fit (loose)
Side play between flywheels
Fit on crankpin (loose)
TAPPET
Fit in guide
Roller fit
Roller end clearance
OIL PUMP
Oil pressure at 1000 RPM
normal operating
2500 RPM
temperature
Shaft to pump clearance
Feed/scavenge inner/outer
gerotor clearance
3-2
NEW COMPONENTS
0.0005-0.0020 in.
0.003-0.013 in.
0.004-0.002 in.
0.0007-0.0022 in.
0.007-0.020 in.
0.009-0.052 in.
0.0020-0.0045 in.
0.0016-0.0041 in.
0.0016-0.0076 in.
0.00005-0.00045 in.
0.0033-0.0020 in.
0.0035-0.0010 in.
0.006 in. total
3.4978 in.
3.502 in.
3.507 in.
3.517 in.
3.527 in.
0.00125-0.00175 in.
0.005-0.025 in.
0.0004-0.0017 in.
0.0008-0.0023 in.
0.0006-0.0013 in.
0.008-0.022 in.
7-12 PSI
10-17 PSI
0.0025 in.
0.003 in.
www.PlanDeGraissage.org
0.013-0.051 mm 0.0035 in.
0.08-0.33 mm 0.025 in
0.10-0.05 mm
0.018-0.056 mm 0.0035 in.
0.18-0.51 mm 0.032 in.
0.23-1.32 mm 0.065 in
0.051-0.114 mm 0.0065 in.
0.041-0.104 mm 0.0065 in.
0.041-0.193 mm 0.0094 in.
0.0013-0.0114 mm 0.00100 in.
0.084-0.051 mm
0.089-0.025 mm
0.15 mm total 0.006 in. total
0.002 in.
0.003 in.
0.006 in.
0.008 in.
88.844 mm 3.5008 in.
88.95 mm 3.505 in.
89.08 mm 3.510 in.
89.33 mm 3.520 in.
89.59 mm 3.530 in.
0.0318-0.0445 mm 0.00200 in.
0.13-0.64 mm 0.030 in.
0.010-0.043 mm 0.0027 in.
0.020-0.058 mm 0.003 in.
0.015-0.033 mm
0.203-0.599 mm 0.026 in.
2
0.5-0.8 kN/cm
2
0.7-1.2 kN/cm
0.064 mm
0.08 mm 0.004 in.
SERVICE WEAR LIMITS
0.089 mm
0.64 mm
0.089 mm
0.81 mm
1.65 mm
0.165 mm
0.165 mm
0.239 mm
0.0254 mm
0.15 mm total
0.05 mm
0.08 mm
0.15 mm
0.20 mm
88.920 mm
89.03 mm
89.15 mm
89.41 mm
89.66 mm
0.0508 mm
0.76 mm
0.069 mm
0.08 mm
0.660 mm
0.10 mm