Buell 2002 P3 - Page 222

2002 Buell P3: Engine 3-75
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12. See Figure 3-134. Install pinion shaft bearing.
a. Lubricate pinion shaft bearing with engine oil.
b. Slip bearing on pinion shaft.
c. Install new retaining ring in groove of pinion shaft
bearing inner race.
13. Install transmission. See 6.14 TRANSMISSION INSTAL-
LATION.
14. Assemble crankcase halves together.
a. Apply a thin coat of DOW CORNING SILASTIC or 3-
M 800 sealant to crankcase joint faces.
b. Slide pinion shaft through outer race in right crank-
case.
c. Attach crankcase halves using hardware shown in
Figure 3-115.
d. Tighten the 5/1618 X 3-1/2 in. fasteners to 15-19 ft-
lbs (20-26 Nm).
e. Tighten the 5/1618 X 2-1/2 in fasteners to 15-19 ft-
lbs (20-26 Nm).
f. Tighten 3/8-in. fastener to 22-27 ft-lbs (30-37 Nm).
15. See Figure 3-135. Install cylinder studs.
a. Pack clean towels into crankcase opening.
b. Place a steel ball into a head screw.
c. The cylinder studs have a shoulder at the lower end.
Place the end of the stud without the shoulder into
the head screw.
d. Install the stud in the crankcase with the shoulder
end down. Use an air gun to drive the stud until the
shoulder reaches the crankcase.
e. Remove air gun. Use a torque wrench to tighten
stud to 10-20 ft-lbs (14-27 Nm).
16. Install piston and cylinder. See 3.6 CYLINDER AND PIS-
TON.
17. Install oil pump. See 3.13 OIL PUMP.
18. See 3.16 GEARCASE COVER AND CAM GEARS.
Install cam gears, gearcase cover, lifter guides and lift-
ers.
19. Install cylinder head. See 3.5 CYLINDER HEAD.
20. Install starter. See 5.7 STARTER.
21. Install shift linkage.
22. Install all primary drive components. This includes
engine sprocket, primary chain, complete clutch assem-
bly, engine sprocket nut and mainshaft nut. See 6.6 PRI-
MARY DRIVE/CLUTCH.
23. Install primary cover. See 6.2 PRIMARY CHAIN.
NOTE
See 1.10 TRANSMISSION/PRIMARY FLUID. Be sure to refill
transmission to proper level with fresh lubricant.
24. See 3.4 ENGINE INSTALLATION and perform the appli-
cable steps.
Figure 3-133. Install Bearing Seal/Spacer
Figure 3-134. Pinion Shaft Bearing
Figure 3-135. Cylinder Studs
7661
1. Bearing/Seal Installer (Part No. HD-42579)
2. Seal/Spacer Installer (Part No. HD-42774)
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1
a0120x3x
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4
1. Head Screw with Ball Inside
2. Cylinder Stud
3. Shoulder on Cylinder Stud
4. Air Gun
7662
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