Buell 2002 S3T, Service Manual

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2002 Buell S3T: Engine 3-21
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ASSEMBLY
CAUTION
Make sure all lapping compound is removed from cylin-
der head and valves after lapping is completed. If lapping
compound contaminates any internal engine compo-
nents or engine oil, excessive engine wear and damage
may result.
1. Wash cylinder head and valves in warm, soapy water to
remove all lapping compound.
2. Scrub valve guide bores with VALVE GUIDE BRUSH
(Part No. HD-34751) and hot, soapy water.
3. Blow dry with compressed air.
4. Apply a liberal amount of engine oil to the valve stem.
5. See Figure 3-25. Insert valve into valve guide (5) and
install lower collar (4).
6. See Figure 3-26. Place a protective sleeve over the valve
stem keeper groove. Coat the sleeve with oil and place a
new seal over the valve stem.
CAUTION
Always use a protective sleeve on the valve stem keeper
groove when installing valve stem seal. If the seal is
installed without using the protective sleeve, the seal will
be damaged.
CAUTION
Do not remove valve after seal is installed. Otherwise,
sharp edges on keeper groove will damage seal.
7. See Figure 3-25. Tap the valve stem seal (3) onto the
valve guide (5) using the VALVE SEAL INSTALLATION
TOOL (Part No. HD-34643A) and DRIVER HANDLE
(Part No. HD-34740). The seal is completely installed
when the tool touches the lower collar (4).
8. See Figure 3-9. Install valve springs (5, 6) and upper col-
lar (8).
9. Compress springs with VALVE SPRING COMPRESSOR
(Part No. HD-34736B).
10. Insert valve keepers (7) into upper collar (8), making
sure they engage groove in valve stem. The keeper gaps
should be equal.
11. Release and remove VALVE SPRING COMPRESSOR.
12. Repeat Steps 4-11 for the remaining valve(s).
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WARNING
1
WARNING
Always wear proper eye protection and gloves when
working with compressed air. Debris or solvent may be
blown out with enough force to penetrate skin or cause
eye injury. Failure to comply could result in death or seri-
ous injury.
13. If front isolator mount was removed, install as follows.
a. Clean residual loctite from threads in engine with a
suitable nonflammable solvent and dry with com-
pressed air.
b. Apply LOCTITE THREADLOCKER 271 (red) to
threads of
new front isolator mount bolts.
c. Apply a thin film of clean HD 20W50 engine oil to
both sides of new thick washers and to bottom of
bolt heads. Exercise caution to avoid mixing oil on
washers with loctite on bolts.
d. Position front isolator mount and secure with two
new front bolts with new thick washers. Tighten
bolts to 60 ft-lbs (81 Nm) initially and then loosen
each bolt one full turn. Tighten bolts again to 60 ft-
lbs (81 Nm).
Figure 3-25. Valve Seal Installation
Figure 3-26. Valve Guide Seal Protector Sleeve
1. Valve Seal
Installation Tool
2. Driver Handle
3. Valve Stem Seal
4. Lower Collar
5. Valve Guide
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2
3
4
5
5686
Protective Sleeve