2007 Buell Lightning: Engine 3-103
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Lapping Pinion Shaft Bearing Outer Race
1. Secure right and left crankcase halves with three crank-
case stud bolts (top center and bottom left and right).
The sprocket shaft bearing outer races and large spacer
must be installed in left crankcase.
2. See Figure 3-148. Obtain CRANKCASE MAIN BEAR-
ING LAPPING TOOL (Part No. HD-96710-40B). Assem-
ble CRANKCASE MAIN BEARING LAP (Part No. HD-
96718-87) to lapping handle. Assemble guide sleeve to
sprocket shaft bearing bushing. Sleeves, for use with
tapered bearing, are assembled to case with bearings
and small spacer collar. Finger-tighten the sleeve parts.
3. Insert lap shaft with arbor assembled through pinion
bearing bushing and into guide sleeve. Tighten arbor
expansion collars using a length of 0.156 in. (3.962 mm)
rod as spanner until arbor begins to drag. Do not adjust
arbor snug in bushing or bushing will develop a condition
where hole is larger at ends than it is in the center.
4. Withdraw arbor far enough to coat lightly with 220 grit
lapping compound. Do not apply a heavy coat.
5. Reposition lap in bushing and turn handle at moderate
hand speed. Work lap back and forth in bushing, as it is
revolved, to avoid grooving and tapering.
6. At frequent intervals, remove lap from crankcase, wash
and inspect bushing. Lapping is completed when entire
bushing surface has a dull, satin finish rather than a
glossy, smooth appearance. If necessary, flush off lap in
cleaning solvent, air dry and apply fresh, light coat of fine
lapping compound.
CHECKING CONNECTING ROD SIDE
PLAY
1. See Figure 3-149. Check connecting rod side play with a
thickness gauge as shown.
2. If side play measurement is greater than service wear
limit listed below, replace flywheel/connecting rod
assembly. The service wear limit is, 0.036 in. (0.8 mm).
Figure 3-148. Lapping Pinion Shaft Bearing Outer Race
with Crankcase Main Bearing Lapping Tool
(Part No. HD-96710-40B)
Figure 3-149. Checking Connecting Rod Side Play
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