Buell P3 - Cylinder and Piston

3-40 2007 Buell P3: Engine
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CYLINDER AND PISTON 3.6
REMOVAL/DISASSEMBLY
1. Strip motorcycle as described under this procedure. See
3.3 STRIPPING MOTORCYCLE FOR ENGINE SER-
VICE.
2. Remove cylinder head. See 3.5 CYLINDER HEAD.
3. Clean crankcase around cylinder base to prevent dirt
and debris from entering crankcase while removing cylin-
der.
4. See Figure 3-70. Turn engine over until piston of cylinder
being removed is at bottom of its stroke.
5. Carefully raise cylinder just enough to permit placing
clean towel under piston to prevent any foreign matter
from falling into crankcase.
NOTE
If cylinder does not come loose, lightly tap a plastic hammer
perpendicular to the cylinder fins. Never try to pry a cylinder
up.
6. Carefully lift cylinder over piston and cylinder studs. Do
not allow piston to fall against cylinder studs. Discard cyl-
inder base gasket.
IMPORTANT NOTE
With cylinder removed, be careful not to bend the cylin-
der studs. The slightest bend could cause a stress riser
and lead to stud failure.
7. Install a 6.0 in. (152 mm) length of 1/2 in. (12.7 mm) ID
plastic or rubber hose over each cylinder stud. This will
protect the studs and the piston.
11WARNING1WARNING
Wear safety glasses or goggles when removing or install-
ing piston pin retaining rings. Piston pin retaining rings
are compressed in the ring groove and can fly out when
removed from the groove, which could result in serious
eye injury. (00293a)
IMPORTANT NOTE
DO NOT re-use piston pin retaining rings. Removal may
weaken retaining rings and they may break or dislodge if
reinstalled resulting in engine damage.
NOTE
Since the piston pin is a loose fit in the piston, the pin will eas-
ily slide out. The pin has tapered ends to help seat the round
retaining rings.
Figure 3-70. Cylinder and Piston
1. Ring set
2. Retaining ring (2)
3. Piston
4. Dowel and o-ring
5. Cylinder
6. Cylinder stud (4)
7. Base gasket
8. Piston pin bushing
9. Connecting rod
10. Piston pin
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