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2002 Buell S3T: Engine
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Flywheel/Connecting Rod Assembly
Replacement
If the flywheel or connecting rods need to be replaced, then
they must be replaced together as one assembly. Return the
flywheel/connecting rod assembly to the factory for service or
replacement.
CLEANING AND INSPECTION
Wash all parts in solvent and blow dry with compressed air.
Flywheel/Connecting Rod Assembly
1.
Replace the flywheel/connecting rod assembly is any of
the following conditions are noted:
●
Connecting rods are bent or twisted.
●
Connecting rods do not fall under their own weight
or are in a bind.
●
The crankshaft (roller) bearing inner race is bur-
nelled, burnt, scored, blued or damaged.
2.
Inspect connecting rods for correct free play.
●
Holding the shank of each rod just above the bear-
ing bore, pull up and down on the connecting rods.
Any discernible up and down movement indicates
excessive lower bearing clearance. Replace the fly-
wheel/connecting rod assembly.
3.
See
Figure 3-80.
Check connecting rod side play.
a.
Insert a feeler gauge between the thrust washer and
the outboard side of the connecting rod.
b.
Replace the assembly if the rod side play exceeds
0.030 inch (0.762 mm).
Fitting Sprocket Bearings
If flywheel end play is within tolerance, and if tapered roller
bearings and races pass visual check and have no apparent
wear, the same set may be reinstalled. Make certain all parts
of bearing are installed in exactly the same order in which
they were removed. If any part of bearing assembly is worn,
entire assembly should be replaced.
Fitting Pinion Bearings
See
Figure 3-75.
A pressed-in bushing in the right crankcase
half is the outer race. The inner race is pressed on the pinion
shaft.
See
Figure 3-83.
To remove pinion shaft inner race, use
TWO
CLAW PULLER (Part No. HD-97292-61), CENTER CAP
(Part HD-95652-43A), and BEARING SEPARATOR (SNAP-
ON TOOLS Stock No. CJ950). Apply heat to race to aid
removal. Four sizes of pinion bearings are available. Pinion
bearing selection at the factory, during engine rebuild, or
replacement of crankcase set or flywheel assembly is based
on the largest measured outside diameter (OD) of the inner
race and the smallest measured inside diameter (ID) of the
outer race (crankcase bushing). A running clearance of
0.0002-0.0008 in. (0.0051-0.0203 mm) is established during
crankcase set or flywheel assembly replacement and engine
rebuild.
Figure 3-80. Checking Connecting Rod Side Play
Figure 3-81. Low Inertia Flywheel and Connecting Rod
Assembly/Factory Inner Race Sizes
8202
b0870x3x
Flywheel
Assembly
Inner Ring
Retaining
Ring
Piston Pin
Bushing
* Paint dot on end of spline
SERVICE WEAR LIMIT: 1.2492 in. (31.7297 mm)
RACE OD
CLASS
IDENTIFICATION*
1.2498-1.2500 in.
(31.7449-31.7500 mm)
A
White
1.2496-1.2498 in.
(31.7398-31.7449 mm)
B
Green
*Paint Dot
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