Buell 2006LIGHTNING MODELS, Service Manual

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2006 Buell Lightning: Engine 3-99
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Replacement
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 PINION SHAFT BEARING OUTER
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.
6. Press new outer race into crankcase flush with inside
edge of cast-in insert.
NOTE
See Figure 3-145. Dimensions are shown for fabrication of
tools used in pressing the outer race into or out of crankcase.
7. 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 PINION
SHAFT BEARING OUTER RACE .
Table 3-32. Outer Pinion Race Service
Wear Limits
Largest ID
measured
1.5672 in. (39.8069 mm)
Roundness of
ID
within 0.0002 in. (0.0051 mm)
Taper within 0.0002 in. (0.0051)
Figure 3-145. 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
.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)
1. Pinion outer race installer
2. Pinion outer race remover
3. Pinion inner race installer
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