2002 Buell P3: Engine 3-37
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Measuring Cylinder Bore
1. Remove any burrs from the cylinder gasket surfaces.
2. See 3.5 CYLINDER HEAD. See Figure 3-70. Install a
head and base gasket, and CYLINDER TORQUE
PLATES (Part No. HD-33446A) and XL EVOLUTION
TORQUE PLATE BOLTS (Part No. HD-33446-86).
Tighten the bolts using the same method used when
installing the cylinder head screws.
NOTE
Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will
vary as much as 0.001 in. (0.025 mm) without torque plates.
3. Take cylinder bore measurement in ring path, starting
about 1/2 in. (12.7 mm) from top of cylinder, measuring
from front to rear and then side to side. Record readings.
4. Repeat measurement at center and then at bottom of
ring path. Record readings. This process will determine if
cylinder is out-of-round (or “egged”) and will also show
any cylinder taper or bulge.
5. See Tabl e 3-9. If cylinder is not scuffed or scored and is
within service limit, see FITTING CYLINDER TO PIS-
TON section.
NOTE
See 3.1 SPECIFICATIONS. If piston clearance exceeds ser-
vice wear limit, cylinders should be re-bored and/or honed to
next standard oversize, and refitted with the corresponding
piston and rings. Do not fit piston tighter than 0.0007 in.
(0.0178 mm).
Measuring Piston
Because of their complex shape, the pistons cannot be accu-
rately measured with standard measuring instruments.
Pistons have an elliptical shape when viewed from the top
and are barrel-shaped when viewed from the side. This barrel
shape is not symmetrical.
Any damage to the piston will change its shape, which will
lead to problems.
Figure 3-70. Measuring Cylinder Bore Using Torque
Plates (Part No. HD-33446A)
Table 3-9. Cylinder Bore
Service Wear Limits
BORE SIZES IN. MM
Standard Bore 3.5008 88.9203
0.005 in. OS bore
(0.127 mm)
3.5050 89.0270
0.010 in. OS bore
(0.254 mm)
3.5100 89.1540
0.020 in. OS bore
(0.508 mm)
3.5200 89.4080
0.030 in. OS bore
(0.762 mm)
3.5300 89.6620
a0010x3x
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