Buell 2006LIGHTNING MODELS, Service Manual, Page: 296 / 638

3-62 2006 Buell Lightning: Engine
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CYLINDER AND PISTON 3.7
REMOVAL/DISASSEMBLY
1. Strip motorcycle as described under 3.3 ENGINE ROTA-
TION FOR SERVICE .
2. Remove cylinder head. See 3.6 CYLINDER HEAD .
3. Clean crankcase around cylinder base to prevent dirt
and debris from entering crankcase while removing cylin-
der.
4. See Figure 3-86. Turn engine over until piston of cylinder
being removed is at bottom of its stroke.
5. Carefully raise cylinder just enough to permit placing
clean towel under piston to prevent any foreign matter
from falling into crankcase.
NOTE
If cylinder does not come loose, lightly tap a plastic hammer
perpendicular to the cylinder fins. Never try to pry a cylinder
up.
6. Carefully lift cylinder over piston and cylinder studs. Do
not allow piston to fall against cylinder studs. Discard cyl-
inder base gasket.
NOTE
With cylinder removed, be careful not to bend the cylinder
studs. The slightest bend could cause a stress riser and lead
to stud failure.
7. Install a 6 in. (152 mm) length of 1/2 in. (12.7 mm) ID
plastic or rubber hose over each cylinder stud. This will
protect the studs and the piston.
1 1
WARNING
1
WARNING
Wear safety glasses or goggles when removing or install-
ing piston pin retaining rings. Piston pin retaining rings
are compressed in the ring groove and can fly out when
removed from the groove, which could result in serious
eye injury. (00293a)
NOTE
DO NOT re-use piston pin retaining rings. Removal may
weaken retaining rings and they may break or dislodge if rein-
stalled resulting in engine damage.
Figure 3-86. Cylinder and Piston
1. Ring set
2. Piston
3. Piston pin
4. Retaining ring (2)
5. Dowel and o-ring
6. Cylinder
7. Base gasket
8. Cylinder stud (4)
9. Connecting rod
10. Piston pin bushing
1
4
2
3
10
5
4
9
6
7
8
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