Buell 2002 P3 Service Manual page 206

HOME
INTAKE CAM GEAR BUSHING IN
GEARCASE COVER.
See Figure 3-98. The intake cam gear bushing must be
installed in its gearcase cover bore using an arbor press. You
will need to orient the bushing in a specific position of rotation
within the cover bore according to the following procedures:
1. See Figure 3-105. Position bushing over bore of gear-
case cover with chamfered edge downward and slot
upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
with cover boss.
2. See Bushing Reaming. After you install a new bushing
in gearcase cover, line-ream the bushing to the correct
size.
PINION SHAFT BUSHING IN GEARCASE COVER
1. See Figure 3-98. Using an arbor press, install pinion
shaft bushing in its gearcase cover so that bushing is
flush with cover boss. There is no need to orient this par-
ticular bushing in any specific position of rotation within
the gearcase cover bore.
2. Although the original pinion shaft bushing is not "pinned,"
the replacement bushing must be secured, from possible
rotation within the cover bore, by installation of a dowel
pin. See Figure 3-106.
(7.137 mm) deep, at top side of boss (side toward top of
gearcase cover), centering the drill bit on the cover bore
circle (hole is drilled half in bushing OD and half in cover
bore ID).
3. Drive a new dowel pin no more than 0.20 in. (5.08 mm)
below the bushing face. Carefully peen edges of hole to
lock the pin in place.
4. See Bushing Reaming. After you install a new bushing
in gearcase cover, line-ream the bushing to the correct
size.
Bushing Reaming
NOTE
●
Installing and reaming crankcase and gearcase cover
bushings may alter the center distances between mating
gears and may result in an increase in gear noise. For
quiet-running gears, the gears should be matched to the
center distances.
●
Bushings in right crankcase half serve as pilots for ream-
ing gearcase cover bushings and must, therefore, be
reamed to size first.
●
After reaming any bushing, check shaft fit in the bushing.
It may be necessary to make a second pass with reamer
to attain proper fit.
Drill a No. 31 hole, 0.281 in.
7684
1. Front Intake Cam Gear Bushing
2. Gearcase Cover
Figure 3-105. Rear Intake Cam Gear Bushing
Installed in Gearcase Cover
7682
Figure 3-106. Drilling Dowel Pin Hole
Slot
Replacement
bushing
requires dowel
pin hole
2002 Buell P3: Engine 3-59