2007 Buell P3: Engine 3-43
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Measuring Cylinder Bore
1. Remove any burrs from the cylinder gasket surfaces.
2. See Figure 3-74. Install a head gasket, base gasket and
o-rings, and CYLINDER TORQUEPLATES (Part No. HD-
33446A) and XL EVOLUTION TORQUE PLATE BOLTS
(Part No. HD-33446-86). Tighten the bolts using the
same method used when installing the cylinder head
screws. See 3.5 CYLINDER HEAD.
NOTE
Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will vary
as much as 0.001 in. (0.025 mm) without torque plates.
3. See Figure 3-74. Take cylinder bore measurement in ring
path, starting about 0.50 in. (12.7 mm) from top of cylin-
der, measuring from front to rear and then side to side.
Record readings.
4. Repeat measurement at center and then at bottom of
ring path. Record readings. This process will determine if
cylinder is out-of-round and will also show any cylinder
taper or bulge.
5. Refer to Table 3-25. If cylinder is not scuffed or scored
and is within service limit, see next section, FITTING
PISTON RINGS.
NOTE
If piston clearance exceeds service wear limit, cylinders
should be re-bored and/or honed to next standard oversize,
and refitted with the corresponding piston and rings. Do not fit
piston tighter than 0.0007 in. (0.0178 mm). See 3.1 SPECIFI-
CATIONS.
Measuring Piston
Because of their complex shape, the pistons cannot be accu-
rately measured with standard measuring instruments.
Pistons have an elliptical shape when viewed from the top
and are barrel-shaped when viewed from the side. This barrel
shape is not symmetrical.
Any damage to the piston will change its shape, which will
lead to problems.
Figure 3-74. Measuring Cylinder Bore Using Torque
Plates (Part No. HD-33446A)
b0306x3x
Table 3-25. Cylinder Bore
Service Wear Limits
BORE SIZES IN. MM
Standard bore 3.5008 88.9203
0.005 in. OS bore
(0.127 mm)
3.5050 89.0270
0.010 in. OS bore
(0.254 mm)
3.5100 89.1540
0.020 in. OS bore
(0.508 mm)
3.5200 89.4080
0.030 in. OS bore
(0.762 mm)
3.5300 89.6620
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