Buell 2002 P3 Service Manual page 183

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NOTE
Since the piston pin is a loose fit in the piston, the pin will
easily slide out. The pin has tapered ends to help seat the
round retaining rings.
9. See Figure 3-68. The arrow at the top of 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 3-68. Spread piston rings outward until they
clear grooves in piston 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. See Connecting Rod Bushing section. If piston pin-
to-bushing clearance exceeds 0.00200 in. (0.05080
mm), replace worn parts.
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.
a0099x3x
V-groove
Figure 3-68. Piston Pin and Piston Identification
3-36 2002 Buell P3: Engine
Checking Gasket Surface
CAUTION
If cylinder gasket surface does not meet flatness specifi-
cations, replace cylinder and piston. Proper tolerances
will extend component life and prevent leaks.
1. See Figure 3-69. 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.
6611
Figure 3-69. Checking Gasket Surfaces