Buell 2002 S3T, Service Manual

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2002 Buell S3T: Engine 3-3
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ITEM NEW COMPONENTS SERVICE WEAR LIMITS
CONNECTING ROD
Piston pin fit (loose) 0.00125-0.00175 in. 0.03175-0.04445 mm 0.00200 in. 0.05080 mm
Side play between flywheels 0.005-0.025 in. 0.127-0.635 mm 0.030 in. 0.762 mm
Fit on crankpin (loose) 0.0004-0.0017 in. 0.0102-0.0432 mm 0.0027 in. 0.0686 mm
Connecting rod race ID 1.6245-1.6250 in.
41.2623-41.2750 mm
1.6270 in. 41.3258 mm
LIFTER
Fit in guide 0.0008-0.0020 in. 0.0203-0.0508 mm 0.0030 in. 0.0762 mm
Roller fit 0.0006-0.0010 in. 0.0152-0.0254 mm 0.0015 in. 0.0381 mm
Roller end clearance 0.008-0.022 in. 0.203-0.559 mm 0.026 in. 0.660 mm
OIL PUMP
Oil
pressure 1000 RPM 7-12 PSI 48-83 kN/m
2
2500 RPM 10-17 PSI 69-117 kN/m
2
Shaft to pump clearance 0.0025 in. 0.0635 mm
Feed/scavenge inner/outer
gerotor clearance
0.003 in. 0.076 mm 0.004 in. 0.102 mm
GEARCASE
Cam gear shaft in
bushing (loose)
0.0007-0.0022 in. 0.0178-0.0559 mm 0.003 in. 0.076 mm
Cam gear shaft end play
(min) (except rear intake)
0.005-0.024 in. 0.127-0.610 mm 0.025 in. 0.635 mm
Rear intake cam gear shaft
end play (min)
0.006-0.024 in. 0.152-0.610 mm 0.040 in. 1.016 mm
FLYWHEEL
Runout
Flywheels at rim 0.000-0.010 in. 0.000-0.254 mm 0.010 in. 0.254 mm
Shaft at
flywheel end
0.000-0.002 in. 0.000-0.051 mm 0.002 in. 0.051 mm
End play 0.001-0.005 in. 0.025-0.127 mm 0.005 in. 0.127 mm
SPROCKET SHAFT BEARING
Outer race fit in
crankcase (tight)
0.0004-0.0024 in. 0.0102-0.0610 mm
Bearing inner race fit
on shaft (tight)
0.0002-0.0015 in. 0.0051-0.0381 mm
PINION SHAFT BEARINGS
Pinion shaft jounal diameter 1.2496-1.2500 in. 31.7398-31.7500 mm 1.2496 in. (min) 31.7398 mm (min)
Outer race diameter in
right crankcase
1.5646-1.5652 in.
39.7408-39.7561 mm
1.5672 in. (max) 39.8069 mm (max)
Bearing running clearance 0.00012-0.00088 in. 0.00305-0.02235 mm
Fit in cover bushing
(loose)
0.0023-0.0043 in. 0.0584-0.1092 mm 0.0050 in. 0.1270 mm