3-44 2007 Buell P3: Engine
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Fitting Cylinder to Piston
Since pistons cannot be accurately measured with standard
measuring instruments, the bore sizes must be measured.
Bore sizes are listed in Table 3-26. Example: A 0.005 in.
(0.127 mm) oversize piston will have the proper clearance
with a bore size of 3.502 in. ± 0.0002 in. (88.951 mm ±
0.0051 mm).
Boring and Honing Cylinder
When cylinder requires oversize reboring to beyond 0.030 in.
(0.762 mm), the oversize limit has been exceeded and cylin-
der must be replaced.
1. Bore cylinder with gaskets and torque plates attached.
Bore to 0.003 in. (0.076 mm) under the desired finished
size.
2. Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing
must be done with the torque plates attached. All honing
must be done from the bottom (crankcase) end of the
cylinder. Work for a 60° crosshatch pattern.
IMPORTANT NOTE
Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and possible
engine failure.
3. Thoroughly wash the cylinder bore with liquid dish soap
and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no evidence of dirt or debris.
11WARNING1WARNING
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye injury.
Wear safety glasses when working with compressed air.
Never use your hand to check for air leaks or to deter-
mine air flow rates. (00061a)
4. Hot rinse the cylinder and dry with moisture free com-
pressed air.
5. Immediately apply a thin film of clean engine oil to a
clean white paper towel and thoroughly wipe the inside
of the cylinder.
NOTE
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.
Table 3-26. Final Cylinder Bore Sizes
BORE SIZES IN. MM
Standard bore* 3.4978 88.8441
0.005 in. OS bore (0.127 mm) 3.502 88.951
0.010 in. OS bore (0.254 mm) 3.507 89.078
0.020 in. OS bore (0.508 mm) 3.517 89.332
0.030 in. OS bore (0.762 mm) 3.527 89.586
*All bore sizes + 0.0002 in. (0.0051 mm)
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