3-2 2002 Buell P3: Engine
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ROCKER ARM
NEW COMPONENTS SERVICE WEAR LIMITS
Shaft fit in bushing (loose) 0.0005-0.0020 in. 0.0127-0.0508 mm 0.0035 in. 0.0889 mm
End clearance 0.003-0.013 in. 0.076-0.330 mm 0.025 in 0.635 mm
Bushing fit in rocker arm (tight) 0.004-0.002 in. 0.102-0.0559 mm
Rocker arm shaft fit in
rocker cover (loose)
0.0007-0.0022 in. 0.018-0.056 mm 0.0035 in. 0.0889 mm
PISTON NEW COMPONENTS SERVICE WEAR LIMITS
Compression ring gap
(top and 2nd)
0.007-0.020 in. 0.178-0.508 mm 0.032 in. 0.813 mm
Oil control ring rail gap 0.009-0.052 in. 0.229-1.321 mm 0.065 in 1.651 mm
Compression
ring side
clearance
Top0.0020-0.0045 in. 0.0508-0.1143 mm 0.0065 in. 0.1651 mm
2nd
0.0016-0.0041 in. 0.0406-0.1041 mm 0.0065 in. 0.1651 mm
Oil control ring side clearance 0.0016-0.0076 in. 0.0406-0.1930 mm 0.0094 in. 0.2388 mm
Pin fit
(loose, at room temperature)
0.00005-0.00045 in.
0.00127-0.01143
mm
0.00100 in. 0.02540 mm
CYLINDER HEAD
NEW COMPONENTS SERVICE WEAR LIMITS
Valve guide in head (tight) 0.0033-0.0020 in. 0.0838-0.0508 mm
Valve seat in head (tight) 0.0035-0.0010 in. 0.0889-0.0254 mm
Head gasket surface (flatness) 0.006 in. total 0.152 mm total 0.006 in. total 0.152 mm total
CYLINDER
NEW COMPONENTS SERVICE WEAR LIMITS
Taper
0.002 in. 0.051 mm
Out of round
0.003 in. 0.076 mm
Warpage
(gasket surfaces)
Top
0.006 in. 0.152 mm
Base
0.008 in. 0.203 mm
Bore diameter
± 0.0002 in.
OS=over size
Standard 3.4978 in. 88.8441 mm 3.5008 in. 88.9203 mm
0.005 OS 3.502 in. 88.951 mm 3.5050 in. 89.0270 mm
0.010 OS 3.507 in. 89.078 mm 3.5100 in. 89.1540 mm
0.020 OS 3.517 in. 89.332 mm 3.5200 in. 89.4080 mm
0.030 OS 3.527 in. 89.586 mm 3.5300 in. 89.6620 mm
CONNECTING ROD NEW COMPONENTS SERVICE WEAR LIMITS
Piston pin fit (loose)
0.00125-0.00175 in.
0.03175-0.04445
mm
0.00200 in. 0.05080 mm
Side play between flywheels 0.005-0.025 in. 0.127-0.635 mm 0.030 in. 0.762 mm
Fit on crankpin (loose) 0.0004-0.0017 in. 0.0102-0.0432 mm 0.0027 in. 0.0686 mm
Connecting rod race ID
1.6245-1.6250 in.
41.2623-41.2750
mm
1.6270 in. 41.3258 mm
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