2007 Buell Lightning: Engine 3-53
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9. Next, with your dial caliper locked to the predetermined
setting, measure the 46° cut at the outer most edge at
the widest point of the circle to determine what cut needs
to be made next.
a. If the 46° cut is to high (towards the combustion
chamber), use the 31° cutter to lower the valve seat
closer to the port.
b. If the 46° cut is too low, use the 60° cutter to raise
the valve seat or move it away from the port.
NOTES
● Due to using the top measurement of our valve seat as a
reference point it will usually be necessary to use the 31°
cutter following the initial 46° cut.
● Always highlight the valve seat with the permanent
magic marker in order to ensure the location of the 46°
valve seat.
10. If the location of the valve seat is not correct, repeat
steps 8 and 9.
11. When you accomplish a complete clean-up of the 46°
angle and the width is at least 0.062 in. (1.575 mm), pro-
ceed to the next step.
12. Select the proper 60° cutter and gently slide the cutter
down the cutter pilot to the valve seat.
13. Remove just enough material to provide an even valve
seat width of 0.040-0.062 in. (1.016-1.575 mm).
14. Remove cutter pilot and wash head thoroughly and dry
completely.
15. Repeat the process on any valve seat that needs ser-
vice.
16. Insert valve to be used in the valve guide and bottom on
the valve seat. Positioning the cylinder head port
upwards and with slight thumb pressure against the
valve, completely fill the port with solvent to verify proper
seal between the valve and the valve seat.
NOTE
Hold pressure against the valve for a minimum of 10 seconds.
If any leakage occurs, examine the valve seat for irregularities
or defects and if necessary repeat the above cutting process.
Figure 3-73. Valve and Seat Dimensions
Intake & Exhaust Valve and Seat
31˚
46˚
60˚
Min. 0.040 in. (1.016 mm)
Max. 0.062 in. (1.575 mm)
b0972x3x
Margin
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