Cylinder And Piston - Buell 2003XB9S Service Manual

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CYLINDER AND PISTON

REMOVAL/DISASSEMBLY
1. Strip motorcycle as described under
MOTORCYCLE FOR ENGINE
2. Remove cylinder head. See
3. Clean crankcase around cylinder base to prevent dirt
and debris from entering crankcase while removing cylin-
der.
4. See Figure 3-91. Turn engine over until piston of cylinder
being removed is at bottom of its stroke.
5. Carefully raise cylinder just enough to permit placing
clean towel under piston to prevent any foreign matter
from falling into crankcase.
NOTE
If cylinder does not come loose, lightly tap a plastic hammer
perpendicular to the cylinder fins. Never try to pry a cylinder
up.
6. Carefully lift cylinder over piston and cylinder studs. Do
not allow piston to fall against cylinder studs. Discard cyl-
inder base gasket.
CAUTION
With cylinder removed, be careful not to bend the cylin-
der studs. The slightest bend could cause a stress riser
and lead to stud failure.
7. Install a 6 in. (152 mm) length of 1/2 in. (12.7 mm) ID
plastic or rubber hose over each cylinder stud. This will
protect the studs and the piston.
11 1
WARNING
Retaining rings are highly compressed in the ring groove
and may "fly out" with considerable force when pried out.
Always wear safety glasses or goggles when removing
or installing retaining rings. Failure to wear safety
glasses or goggles could result in death or serious
injury.
CAUTION
DO NOT re-use piston pin retaining rings. Removal may
weaken retaining rings and they may break or dislodge if
reinstalled resulting in engine damage.
3.4 STRIPPING
SERVICE.
3.6 CYLINDER HEAD.
WARNING
b0962x3x
1
2
3
4
9
10
6
7
8
1. Ring set
2. Piston
3. Piston pin
4. Retaining ring (2)
5. Dowel and o-ring
6. Cylinder
7. Base gasket
8. Cylinder stud (4)
9. Connecting rod
10. Piston pin bushing
Figure 3-91. Cylinder and Piston
2003 Buell XB9S: Engine
3.7
4
5
3-63