Buell 2002 X1 Handbook page 156

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9. Mark each pin boss with either an "F" or an "R" to indi-
cate front or rear cylinder, respectively. See
The arrow at the top of 1200cc pistons must always point
toward the front of the engine.
CAUTION
Handle the piston with extreme care. The alloy used in
these pistons is very hard. Any scratches, gouges or
other marks in the piston could score the cylinder during
engine operation and cause engine damage.
10. See Figure 3-31. Spread piston rings (6) outward until
they clear grooves in piston (3) and lift off.
CLEANING AND INSPECTION
1. Soak cylinder and piston in an aluminum-compatible
cleaner/solvent until deposits are soft, then clean with a
brush. Blow off loosened carbon and dirt particles and
wash in solvent.
2. Clean oil passage in cylinder with compressed air.
3. Clean piston ring grooves with a piece of compression
ring ground to a chisel shape.
4. Examine piston pin to see that it is not pitted or scored.
5. Check piston pin bushing to see that it is not loose in
connecting rod, grooved, pitted or scored.
a. A piston pin properly fitted to upper connecting rod
bushing has a 0.00125 to 0.00175 in. (0.03175-
0.04445 mm) clearance in bushing.
b. If piston pin-to-bushing clearance exceeds 0.00200
in. (0.05080 mm), replace worn parts. See
NECTING ROD BUSHING
6. Clean piston pin retaining ring grooves.
7. Examine piston and cylinder for cracks, burnt spots,
grooves and gouges.
8. Check connecting rod for up and down play in lower
bearings. When up and down play is detected, lower
bearing should be refitted. This requires removing and
disassembling engine crankcase.
Checking Gasket Surface
CAUTION
If either cylinder gasket surface does not meet flatness
specifications, replace cylinder and piston. Proper toler-
ances will extend component life and prevent leaks.
1. See Figure 3-33. Check cylinder head gasket surface for
flatness.
a. Lay a straightedge across the surface.
b. Try to insert a feeler gauge between the straight-
edge and the gasket surface.
c. If cylinder head gasket surface is not flat within
0.006 in. (0.152 mm), replace cylinder and piston.
2. Check cylinder base gasket surface for flatness.
a. Lay a straightedge across the surface.
b. Try to insert a feeler gauge between the straight-
edge and the gasket surface.
c. If cylinder base gasket surface is not flat within
0.008 in. (0.203 mm), replace cylinder and piston.
3-24
Figure 3-32.
CON-
on page 3-28.
b0057a3x
V-Groove
Figure 3-32. Piston Pin and Piston Identification
6611
Figure 3-33. Checking Gasket Surfaces
2002 Buell X1: Engine