Buell 2006LIGHTNING MODELS, Service Manual, Page: 302 / 638

3-68 2006 Buell Lightning: Engine
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Connecting Rod Bushing
Removal/installation
When connecting rod bushing is worn to excessive pin clear-
ance (0.002 in. or more) (0.051 mm) it must be replaced.
1. See Figure 3-97. Secure connecting rod with CON-
NECTING ROD CLAMPING TOOL (Part No. HD-95952-
33B).
2. See Figure 3-98. Attach PISTON PIN BUSHING TOOL
(Part No. HD-95970-32D) to the connecting rod.
NOTE
See Figure 3-99. The receiver cup fits on one side of the rod
while the driver fits on the opposite side as shown.
3. Use two box wrenches and push worn bushing from con-
necting rod.
4. Remove piston pin bushing tool from connecting rod.
5. Remove bushing from receiver cup.
6. See Figure 3-100. Place new bushing between connect-
ing rod and driver.
NOTE
The driver must be attached facing the opposite direction as it
was for removal of the bushing.
7. Clean up and size bushing to 0.0010-0.0005 in.
(0.0254-0.0127 mm) undersize using REAMER (Part
No. HD-94800-26A). Sizing bushing with less than
0.00125 in. (0.03175 mm) clearance can result in a
bushing loosening and/or seized pin in rod.
8. Hone bushing to final size using WRIST PIN BUSHING
HONE (Part No. HD-35102). Use a liberal amount of
honing oil to prevent damage to hone or bushing. Use
care to prevent foreign material from falling into the
crankcase.
Figure 3-97. Connecting Rod Clamping Tool
(Part No. HD-95952-33B)
Figure 3-98. Connecting Rod Bushing Remover/Installer
(Part No. HD-95970-32D)
b1027x3x
1. Hex cylinder
2. Threaded rod
3. Flat washer
4. Nice bearing
5. Driver (2 way)
6. Receiver cup
7. Nut
d0190x3x
1
3
4
6
7
5
2
Figure 3-99. Removing Wrist Pin Bushing
Figure 3-100. Installing New Wrist Pin Bushing
1. Remover side of driver
2. Receiver cup
2
1
b1025x3x
1. Installer side of driver
2. Oil slot in bushing
3. Oil hole in connecting rod
3 2
1
b1026x3x