Buell 2003XB9S, Service Manual

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2003 Buell XB9S: Engine 3-97
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NOTE
If either inner or outer race show wear, measure both races to
confirm correct bearing fit.
1. Use a dial bore gauge to measure and record ID of outer
race. Take four measurements on ID where bearing roll-
ers ride.
a. If the largest measurement is larger than 1.5672 in.
(39.8069 mm) or the required lapping to remove
wear marks would enlarge bore beyond 1.5672 in.,
continue at Step 5.
b. If largest measurement is 1.5672 in. (39.8069 mm)
or less, cover the cam bearings with masking tape to
prevent debris from entering bearings. Assemble
crankcase halves.
NOTE
The next step requires lapping the outer race. To keep
sprocket shaft and pinion shaft bearings aligned the lap must
be supported by an adaptor or pilot in the left crankcase half.
2. See LAPPING ENGINE RIGHT MAIN BEARING RACE.
Lap race until all wear marks are removed.
3. Measure and record ID of race at four places.
4. Check measurements against the specifications listed in
Table 3-32.
a. If lapping increased bore ID to larger than 1.5672 in.
(39.8069 mm), go to Step 5.
b. If roundness or taper do not meet specifications,
continue lapping until specifications are met.
c. If all specifications are met, continue at Step 7 to
remove and size inner race.
5. Press the outer race from the right crankcase. Press
new outer race into crankcase flush with inside edge of
cast-in insert.
NOTE
See Figure 3-146. Dimensions are shown for fabrication of
tools used in pressing the outer race into or out of crankcase.
6. The new outer race must be lapped slightly to true and
align with left case bearing and to meet the following
specifications in
Table 3-33. See LAPPING ENGINE
RIGHT MAIN BEARING RACE .
Table 3-32. Outer Pinion Race Service
Wear Limits
Largest ID
measured 1.5672 in. (39.8069 mm) or less
Roundness of
ID within 0.0002 in. (0.0051 mm)
Taper within 0.0002 in. (0.0051)
Figure 3-146. Pinion Shaft Bearing Tools
Table 3-33. New Component Specifications
Outer Race ID 1.5646-1.5652 in. (39.7408-39.7561
mm)
Roundness within 0.0002 in. (0.0051 mm)
Taper within 0.0002 in. (0.0051 mm)
Surface finish 16 RMS
Pinion outer race
installation
Pinion outer race
removal
Pinion inner race
installation
.187" (4.75 mm)
2.00"
(50.8 mm)
1.00
(25.4 mm)
1.560"
(39.62 mm)
1.560"
(39.62 mm)
.187" (4.75 mm)
5/16"
(7.94 mm)
DRILL
5/16"
(7.94 mm)
DRILL
1.00"
(25.4 mm)
1.50" (38.1 mm)
1.272" (32.31 mm)
1.262" (32.05 mm)
1.145" (29.08 mm)
1.135" (28.83 mm)
5.50" (139.7 mm)
a0109x3x
1.00
(25.4 mm)