Buell P3 2003 - Page 219

2003 Buell P3: Engine 3-65
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Cam gears are individually selected for each specific gear
cover through sophisticated computer-aided measuring tech-
niques in a controlled environment. Each gear is assigned an
individual color code based on its diameter (measured with
gauge pins). When cam gears are replaced, always use the
same color code as found on gears being replaced to ensure
that the gear operation remains as quiet as possible. For
location of cam gear color codes, see Figure 3-106. Pinion
gear and large gear on intake cam are one size only. No
selective sizing is possible. If damaged, replace both gears
as a pair.
NOTE
On flywheel pinion shaft, a paint dot is located on the shaft
perimeter near the centerline of the keyway. This dot identi-
fies the pinion shaft inner race size. Do not use this dot to
select pinion gear size.
See Ta bl e 3-29. Compare the previously measured diameter
of each gear with the specifications (listed in inches) shown in
the table to determine amount of wear on gear teeth.
NOTE
Prior to changing any cam gears, check gear shaft fit within
corresponding bushings. Worn bushings can cause excessive
backlash.
Figure 3-106. Cam and Pinion Gear Color Code Location
and Timing Mark Indexing
1. Exhaust cam gear (1w)
2. Intake cam gear (2w)
3. Pinion gear
4. Color code
1
2
3
4
7687
Table 3-29. Cam and Pinion Gear Color Code and Diameter
GEAR NO. & POSITION
2
INBOARD
2
OUTBOARD
13
COLOR CODE
(1 paint dot)
Intake Intake Exhaust Pinion
RED 1.9025-1.9029
(48.323-48.333)
1.9025-1.9029
(48.323-48.333)
WHITE 1.9020-1.9024
(48.310-48.321)
1.9020-1.9024
(48.310-48.321)
GREEN 1.9015-1.9019
(48.298-48.308)
1.9015-1.9019
(48.298-48.308)