Buell X1 2002 Service Manual page 202

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Pinion Shaft Bushing Reaming (Gearcase
Cover)
NOTE
A newly installed pinion shaft bushing in the gearcase cover
must be line reamed, using both the right crankcase half and
Pilot (Part No. HD-94812-87) as pilots for the reamer, to
establish correct clearance and to ensure proper 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 3-62. Pinion shaft bushing (16) must be
installed in gearcase cover (17) as described in
BUSHING INSTALLATION (TO
gearcase cover to right crankcase half (10), which has
been disassembled from left crankcase half, securing
with a minimum of three mounting screws.
2. See Figure 3-70. Install PINION SHAFT BUSHING
REAMER PILOT (Part No. HD-94812-87) into right
crankcase roller race. Insert PINION SHAFT BUSHING
REAMER (Part No. HD-94812-1) through the pilot.
3. 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.
4. Separate gearcase cover from right crankcase half.
Inspect bushing for proper pinion shaft fit. Repeat line
reaming operation if necessary.
5. Remove pilot from right crankcase roller race. Thor-
oughly clean gearcase cover, removing all metal chips/
shavings. Blow out all oil passages using compressed
air.
ASSEMBLY/INSTALLATION
1. See Figure 3-71. Install oil pump drive gear (5) and pin-
ion gear on pinion shaft.
a. Slide oil pump gear drive gear (5) over pinion
shaft (1). Drive gear must align with shaft key (4).
b. Align keyway (3) in ID of pinion gear with shaft
key (4).
c. Slide pinion gear over shaft key (4) and against oil
pump drive gear (5).
2. See Figure 3-62. Install nut (11).
a. Clean threads on pinion shaft and nut.
b. See Figure 3-72. Install CRANKSHAFT LOCKING
TOOL (Part No. HD-43984) to gearcase with "Side
A" facing out, over pinion shaft, with two screws.
c. Apply several drops of LOCTITE THREADLOCKER
262 (red) to threads of nut.
d. Install nut to pinion shaft. Tighten nut to 35-45 ft-lbs
(48-61 Nm).
3. Liberally apply engine oil to bushings, shafts, and gears.
Install all cam gears into bushings of right crankcase
half, properly aligning timing marks of cam gears and
pinion gear. See Figure 3-64.
NOTE
Because of the larger diameter additional gear (which
meshes with the pinion gear) on the outboard end of the rear
intake (15-2) cam gear, the rear exhaust (15-1) and front
intake (15-3) cam gears must both be installed before the
rear intake (15-2) cam gear is installed.
3-48
CAM
CRANKCASE). Attach
3545a
1 2
1. Pilot (Part No. HD-94812-87)
2. Reamer (Part No. HD-94812-1)
Figure 3-70. Line Reaming Pinion Shaft Bushing
1
2
3
4
5
1. Pinion Shaft
2. Timing Mark on Pinion Gear
3. Keyway
4. Shaft Key
5. Oil Pump Drive Gear
Figure 3-71. Aligning Pinion Gear
b0337a3x
Figure 3-72. Crankshaft Locking Tool (HD-43984)
2002 Buell X1: Engine