Buell S1 Lightning 1996 Manual page 149

Bushing Inspection and Removal
1. See Figure 3-51. Bushings (7, 8, 13, 14, 15 and 16) are
press fit in gearcase cover (17) and crankcase. Inspect
each bushing against its corresponding cam gear shaft
or pinion gear shaft. See
Table 3-10. Gear Shaft Specifications
CORRECT
GEAR SHAFT
CLEARANCE
Cam 0.0007-0.0022 in.
(0.018-0.056 mm)
Pinion 0.0023-0.0043 in.
(0.058-0.109 mm)
2. See Figure 3-55. Use a
PULLER (Part No. HD-95760-69A)
from gearcase cover and crankcase.
Bushing Installation
CAM GEAR BUSHINGS IN RIGHT
CRANKCASE HALF
1. See Figure 3-57. Each cam gear bushing (1), to be
installed in right crankcase half (2), must be positioned in
crankcase bore with its oiling slot at exact top of bore (12
o'clock position).
2. Using an arbor press, install each bushing in its crank-
case bore so that bushing shoulder contacts crankcase
boss.
3. After you install a new bushing in right crankcase half,
ream the bushing to correct size. See
ING on page 3-44.
CAM GEAR BUSHINGS (EXCEPT REAR INTAKE
BUSHING) IN GEARCASE COVER
1. See Figure 3-51. Using an arbor press, install each bush-
ing (7, 8 and 14) in its gearcase cover (17) bore so that
bushing shoulder contacts cover boss. There is no need
to orient these particular bushings in any specific position
of rotation within gearcase cover bores.
2. After you install a new bushing in gearcase cover, line-
ream the bushing to correct size. See
ING on page 3-44.
REAR INTAKE CAM GEAR BUSHING IN
GEARCASE COVER.
1. See Figure 3-51. Rear intake cam gear bushing (15)
must be installed in its gearcase cover (17) bore using an
arbor press. You will need to orient the bushing in a spe-
cific position of rotation within the cover bore, and will
need to drill a lubrication hole in the bushing, according
to the following procedures
www.PlanDeGraissage.org
Table 3-10.
SERVICE WEAR
LIMIT
0.003 in.
(0.08 mm)
0.005
(0.13 mm)
BUSHING AND BEARING
to remove bushings
BUSHING REAM-
BUSHING REAM-
2806a
Bushing and Bearing Puller
(Part No. HD-95760-69A)
Figure 3-55. Removing Bushing
xlh0355
Slot
1. Rear intake cam gear bushing
2. Gearcase cover
Figure 3-56. Rear Intake Cam Gear Bushing
Installed in Gearcase Cover
2. See Figure 3-56. Position bushing (1) over bore of gear-
case cover (2) with chamfered edge downward and slot
upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
with cover boss.
3. Drill a 5/32 in. (3.97 mm) diameter hole through bushing
using existing hole in gearcase cover as a guide.
4. After you install a new bushing in gearcase cover, line-
ream the bushing to the correct size. See
REAMING on page 3-44.
Drill 5/32 in.
(3.97 mm)
BUSHING
3-43