Cylinder And Piston - Buell 2002 P3 Service Manual

HOME

CYLINDER AND PISTON

REMOVAL/DISASSEMBLY
1. See 3.3 STRIPPING MOTORCYCLE FOR ENGINE
REPAIR/REMOVAL. Strip motorcycle as described
under this procedure.
2. Remove cylinder head. See
3. Clean crankcase around cylinder base to prevent dirt
and debris from entering crankcase while removing cyl-
inder.
4. See Figure 3-67. 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 6.0 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 remov-
ing 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.
8. Insert an awl in the recessed area below the piston pin
bore and pry out the piston pin retaining rings. To prevent
the ring from flying out, place your thumb over the retain-
ing ring.
3.5 CYLINDER HEAD.
WARNING
a0023x3x
1
10
2
9
8
7
1. Ring Set
2. Retaining Ring (2)
3. Piston
4. Dowel and O-ring
5. Cylinder
6. Cylinder Stud (4)
7. Base Gasket
8. Piston Pin Bushing
9. Connecting Rod
10. Piston Pin
Figure 3-67. Cylinder and Piston
2002 Buell P3: Engine
3.6
2
3
4
4
5
6
3-35