Buell 2002 P3 Service Manual page 203

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REMOVAL/DISASSEMBLY
1. See Figure 3-98. Thoroughly clean area around gear-
case cover and tappets. Blow loose dirt from crankcase
with compressed air.
2. Remove any parts that will interfere with gearcase disas-
sembly.
3. See 3.5 CYLINDER HEAD. Remove push rods.
4. See 3.15 HYDRAULIC
ers.
5. Check for minimum cam gear end play. Record readings.
6. See 7.8 IGNITION MODULE/ CAM POSITION SEN-
SOR. Remove cam position sensor and rotor from gear-
case cover.
7. Place a pan under gearcase to collect oil. Remove cover
screws. Carefully remove gearcase cover. Discard old
gasket.
NOTE
If cover does not come loose on removal of screws, tap lightly
with a plastic hammer. Never pry cover off.
8. Remove cam gears.
NOTE
Nut is secured by LOCTITE
nut threads.
9. Remove nut. Slide pinion gear and oil pump drive gear
off pinion shaft.
CLEANING AND INSPECTION
1. Thoroughly clean gearcase compartment, gearcase
cover and gears in solvent to remove oil and carbon
deposits.
2. Blow out all cover oil passages and bushings with com-
pressed air.
3. Clean old gasket material from gearcase and cover faces
with cleaning solvent.
Cam and Pinion Gear Identification,
Inspection, and Selection
See Figure 3-99. Cam lobes are stamped with a number (1 or
2) followed by a letter ("W"). The number (1 or 2) identifies the
cam location/function and the letter ("W") indicates model
year application:
2W=Intake
1W = Exhaust
See Figure 3-100. Measure the gear diameter with a
micrometer over 0.108 in. (2.743 mm) diameter gauge pins
on opposite sides of the gear. The pins are of the proper size
to fit between the contacting surfaces of the gear teeth. Gear
diameter should be measured in at least two places 90°
apart. Use GAUGE PIN SET (Part No. HD-38361) when
measuring pinion and cam gear sizes.
3-56 2002 Buell P3: Engine
LIFTERS. Remove hydraulic lift-
®
thread locker 262 (red) on the
a0075x3x
2W
Figure 3-99. Cam Identification
7673
Figure 3-100. Measuring Gear Size
Cam gears are individually selected for each specific gear
cover through sophisticated computer-aided measuring tech-
niques in a controlled environment. Each gear is assigned an
individual color code based on its diameter (measured with
gauge pins). When cam gears are replaced, always use the
same color code as found on gears being replaced to ensure
that the gear operation remains as quiet as possible. For
location of cam gear color codes, see
gear and large gear on intake cam are one size only. No
selective sizing is possible. If damaged, replace both gears
as a pair.
NOTE
On flywheel pinion shaft, a paint dot is located on the shaft
perimeter near the centerline of the keyway. This dot identi-
fies the pinion shaft inner race size. Do not use this dot to
select pinion gear size.
See Table 3-12. Compare the previously measured diameter
of each gear with the specifications (listed in inches) shown in
the table to determine amount of wear on gear teeth.
NOTE
Prior to changing any cam gears, check gear shaft fit within
corresponding bushings. Worn bushings can cause exces-
sive backlash.
Identify cams by
stamped number
Gauge Pin Set
(Part No. HD-38361)
Figure 3-101. Pinion