Buell 2002 X1 Handbook page 298

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DISASSEMBLY/ASSEMBLY
1 1
WARNING WARNING
An open flame or spark may cause a fuel tank explosion
if all traces of fuel are not purged from the tank. Use
extreme caution when servicing fuel tanks. Gasoline is
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious injury.
1. Drain fuel tank before disassembly.
a. Using suitable external fuel pump, such as a Gas
Caddy, pump fuel from tank and into suitable clean
container.
b. See instructions for external fuel pump for correct
use.
2. See Figure 4-90. Remove fuel filler cap (3) with attached
O-ring (4).
3. Remove screws (5) from fuel cap flange (9).
4. Remove fuel cap flange and fuel cap boot (6).
5. Detach vent valve fitting (10) and vent valve (8) from fuel
cap flange.
6. For all fuel pump removal and repair instructions, see
4.40 FUEL PUMP.
7. Assemble in reverse order. Note that if fuel pump is
removed, it must be reinstalled before fuel cap flange.
a. Apply HYLOMAR to fuel cap boot, fuel cap flange
and top of fuel tank.
b. See Figure 4-91.
(1.8-2.0 Nm) in the order shown.
8. Install vent valve and fitting. See
VALVE.
9. Perform Fuel Tank Pressure Test.
CLEANING AND INSPECTION
1 1
WARNING WARNING
An open flame or spark may cause a fuel tank explosion
if all traces of fuel are not purged from the tank. Use
extreme caution when servicing fuel tanks. Gasoline is
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious injury.
Clean tank interior with commercial cleaning solvent or a
soap and water solution.
1. Plug all tank openings except fuel cap hole.
2. Add cleaning agent. Replace fuel cap to seal tank.
3. Shake tank to agitate agent.
4. Thoroughly flush fuel tank after cleaning. Allow tank to
air dry.
5. Carefully inspect fuel hose and vent hose for damage,
wear or general deterioration. Replace as necessary.
4-102
Tighten screws to 16-18 in-lbs
4.38 FUEL TANK VENT
b0740a4x
3
4
2
1
5
6
14
1. Screw (2)
2. Rear Tank Mount
3. Fuel Cap
4. O-Ring
5. Screw (8)
6. Fuel Cap Boot
7. Fuel Tank
8. Vent Valve
9. Fuel Cap Flange
10. Vent Valve Fitting
11. Vent Hose
12. Cable Strap
13. O-Ring
14. Decal
Figure 4-90. Fuel Tank
7103
6
1
8
Figure 4-91. Tightening Sequence (Typical)
10
12
13
11
9
7
8
3
7
2
5
4
2002 Buell X1: Fuel System