Buell 2002 P3 Service Manual page 207

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CAM GEAR BUSHINGS IN
RIGHT CRANKCASE HALF
1. Separate two halves of crankcase, if not already accom-
plished. Place right crankcase half on flat surface with
gearcase side upward. Bushing to be reamed must be
oriented as shown in Figure 3-103.
2. See Figure 3-107. Position CAMSHAFT BUSHING
REAMER PILOT (Part No. B-43988) onto gearcase side
of crankcase half; upper right and lower left indexing
holes in pilot must be placed over dowels in crankcase
half. Insert two bolts (supplied with pilot) through two
remaining holes in pilot, and into threaded holes of
crankcase half. Tighten bolts securely.
3. Insert REAMER (Part No. HD-38871-2) through pilot
hole and into bushing while turning reamer clockwise.
Continue turning reamer clockwise through bushing until
smooth shank of reamer passes through hole in pilot.
4. Detach reamer from handle. Pull reamer out opposite
side of crankcase half.
5. Thoroughly clean right crankcase half, removing all
metal chips/shavings. Blow out all oil passages using
compressed air.
EXHAUST GEAR BUSHING IN GEARCASE COVER
NOTE
Newly installed cam gear bushings in the gearcase cover
must be line reamed, using the right crankcase half as a pilot
for the reamer, to establish correct clearance and to ensure
perfect alignment. If crankcase halves are not separated on
your motorcycle, use a spare right crankcase half to perform
the following line reaming procedures.
1. See Figure 3-98. Bushings to be reamed must be
installed in gearcase cover as described in
INSTALLATION. Attach gearcase cover to right crank-
case half, which has been disassembled from left crank-
case half, securing with a minimum of three mounting
screws.
2. Insert REAMER (Part No. HD-38871-2) through the pre-
viously reamed cam gear bushing in right crankcase half,
which is in line with exhaust bushing to be reamed in
gearcase cover.
3. Turn reamer clockwise through bushing in cover until
reamer bottoms. Then give reamer one complete clock-
wise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.
4. Separate gearcase cover from right crankcase half.
Inspect bushings for proper cam gear shaft fit. Repeat
line reaming operation if necessary.
Safety glasses or goggles must be worn while removing
metal chips/shavings. Failure to wear safety glasses or
goggles could result in death or serious injury.
5. Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.
INTAKE CAM GEAR BUSHING IN
GEARCASE COVER
3-60 2002 Buell P3: Engine
7739
Camshaft Bushing Reamer
Pilot (Part No.B-43988)
Figure 3-107. Reaming Cam Gear Bushing in Right
A newly installed intake cam gear bushing in the gearcase
cover must be line reamed, using the right crankcase half as
a pilot for the reamer, to establish correct clearance and to
ensure perfect alignment. If crankcase halves are not sepa-
rated on your motorcycle, use a spare right crankcase half to
perform the following line reaming procedures.
1. See Figure 3-98.
installed in gearcase cover as described in BUSHING
INSTALLATION.
2. Identify the previously reamed intake cam gear bushing
in right crankcase half, which has been disassembled
from left crankcase half. Insert the shank end of REAR
BUSHING
INTAKE CAMSHAFT BUSHING REAMER (Part No. HD-
94804-67) through gearcase side of this bushing.
3. With reamer inserted into bushing in right crankcase half,
attach gearcase cover to right crankcase half, securing
with a minimum of three mounting screws.
4. Turn reamer clockwise through bushing in gearcase
cover until reamer bottoms. Then give reamer one com-
plete clockwise turn to size the bushing. Continue turning
reamer clockwise while extracting reamer from bushing.
5. Separate gearcase cover from right crankcase half.
Inspect bushing for proper cam gear shaft fit. Repeat line
reaming operation if necessary.
Safety glasses or goggles must be worn while removing
metal chips/shavings. Failure to wear safety glasses or
goggles could result in death or serious injury.
6. Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.
PINION SHAFT BUSHING IN GEARCASE COVER
A newly installed pinion shaft bushing in the gearcase cover
must be line reamed, using both the right crankcase half and
Part No. HD-94812-87
correct clearance and to ensure proper alignment. If crank-
Crankcase Half
NOTE
Intake cam gear bushing must be
NOTE
as pilots for the reamer, to establish