3-70 2003 Buell P3: Engine
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PINION SHAFT BUSHING IN GEARCASE COVER
NOTE
A newly installed pinion shaft bushing in the gearcase cover
must be line reamed, using both the right crankcase half and
Part No. HD-94812-87 as pilots for the reamer, to establish
correct clearance and to ensure proper alignment. If crank-
case halves are not separated on your motorcycle, use a
spare right crankcase half to perform the following line ream-
ing procedures.
1. See Figure 3-103. Pinion shaft bushing must be installed
in gearcase cover as described in BUSHING INSTALLA-
TION. Attach gearcase cover to right crankcase half,
which has been disassembled from left crankcase half,
securing with a minimum of three mounting screws.
2. See Figure 3-114. Install PINION SHAFT BUSHING
REAMER PILOT (Part No. HD-94812-87) into right
crankcase roller bearing. Insert PINION SHAFT BUSH-
ING REAMER (Part No. HD-94812-1) through the pilot.
3. Turn reamer clockwise through bushing in gearcase
cover until reamer bottoms. Then give reamer one com-
plete clockwise turn to size the bushing. Continue turning
reamer clockwise while extracting reamer from bushing.
4. Separate gearcase cover from right crankcase half.
Inspect bushing for proper pinion shaft fit. Repeat line
reaming operation if necessary.
11WARNING1WARNING
● Safety glasses or goggles must be worn while
removing metal chips/shavings. Failure to wear
safety glasses or goggles could result in death or
serious injury.
● Low pressure compressed air can blow debris into
your face and eyes. Always wear eye protection or a
face shield when using pressurized air. Failure to
take adequate safety precautions could result in
death or serious injury.
5. Remove pilot from right crankcase roller race. Thor-
oughly clean gearcase cover, removing all metal chips/
shavings. Blow out all oil passages using compressed
air.
Figure 3-114. Line Reaming Pinion Shaft Bushing
7716
1. Pilot (Part No. HD-94812-87)
2. Reamer (Part No. HD-94812-1)
3. RIght crankcase
4. Gearcase cover
5. Pinion bushing
21 3 4
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