Buell 2002 X1 Handbook page 160

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Connecting Rod Bushing
When connecting rod bushing is worn to excessive pin clear-
ance (0.002 in. or more) (0.051 mm) it must be replaced.
1. See Figure 3-40. Install plastic hoses (3) over studs.
2. Secure connecting rod with CONNECTING ROD
CLAMPING TOOL (2) (Part No. HD-95952-33B).
NOTE
If CONNECTING ROD CLAMPING TOOL holes are too
small, enlarge the holes in the tool.
3. See Figure 3-41. Attach PISTON PIN BUSHING TOOL
(Part No. HD-95970-32D) to the connecting rod. The
receiver cup (1) fits on one side of the rod while the
driver (2) fits on the opposite side as shown.
4. Use two box wrenches and push worn bushing from con-
necting rod.
5. Remove piston pin bushing tool from connecting rod.
6. Remove bushing from receiver cup.
7. Attach PISTON PIN BUSHING TOOL (Part No. HD-
95970-32D) to connecting rod. Place new bushing
between connecting rod and driver.
NOTE
The driver must be attached facing the opposite direction as it
was for removal of the bushing.
8. Clean up and size bushing to 0.0010-0.0005 in.
(0.0254-0.0127 mm) undersize using REAMER (Part
No. HD-94800-26A). Sizing bushing with less than
0.00125 in. (0.03175 mm) clearance can result in a
bushing loosening and/or seized pin in rod.
9. Hone bushing to final size using WRIST PIN BUSHING
HONE (Part No. HD-35102). Use a liberal amount of
honing oil to prevent damage to hone or bushing. Use
care to prevent foreign material from falling into the
crankcase.
CAUTION
Replace bent connecting rods. Do not attempt to
straighten. Straightening rods by bending will damage
the bearing on the crank pin and the piston pin bushing.
Installing bent connecting rods will damage cylinder and
piston beyond repair.
3-28
6758
1
1. Piston Pin Bushing Tool (Part No. HD-95970-32D)
2. Rod Clamping Tool (Part No. HD-95952-33B)
3. Plastic Hose
Figure 3-40. Installing New Piston Pin Bushing
1. Receiver Cup
2. Driver
3. Washer
4. Nut
5. Bolt
6. Bearing
2
1
5
Figure 3-41. Piston Pin Bushing Tool Assembly
for Bushing Removal
3
2
6
4
3
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2002 Buell X1: Engine