Buell 2002 X1 Handbook page 299

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INSTALLATION
1. Place fuel tank on frame and install fuel tank cover and
fuel tank mount. Tighten mount screws to 9-11 ft-lbs (12-
15 Nm). See 2.35 FUEL TANK
CAUTION
Avoid pinching wiring harness and vent hose between
fuel tank and frame during tank installation. Pinched
hoses will negatively affect vehicle operation.
2. See Figure 4-90. Connect vent hose (11) to vent valve
fitting (10). Clamp hose to fitting with a new cable strap
(12).
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WARNING WARNING
Always make sure fuel hoses are seated against the
component they connect to and that hose clamps are
properly tightened and positioned on straight section of
fitting and not on the fitting barb. Failure to comply may
result in fuel leakage which could result in death or seri-
ous injury.
The barb is the larger outside diameter portion (bump) on the
fuel fitting.
3. Connect fuel hose to fuel outlet with a new clamp. Make
sure to push fuel hose all the way on to fitting and posi-
tion hose clamp on fitting side of barb.
4. Attach 4-place fuel pump connector [86].
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WARNING WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
5. Install seat. See 2.40 SEAT.
Use a good quality unleaded gasoline (91 pump octane or
higher). Octane rating is usually found on the pump.
6. Fill fuel tank. Turn ignition key ON and listen for fuel
pump activation.
7. Carefully inspect for leaks.
2002 Buell X1: Fuel System
COVER.
NOTE
NOTE
FUEL TANK PRESSURE TEST
The fuel tank is a sealed, pressure-tested assembly when it
leaves the factory. If the fuel cap flange seal is broken the fuel
tank must be pressure tested as listed below before installa-
tion.
1. With fuel filter removed, gas cap installed and fuel vent
valve installed, spray soap and water solution around
fuel cap flange and fuel vent valve fitting.
2. Connect air hose to fuel vent valve. Shake the tank sev-
eral times to seat the ball in the vent valve.
Fuel tank must be pressurized slowly or fuel vent will snap
shut and tank will not be pressurized. Slowly remove the fuel
cap when complete to verify that tank was pressurized during
test.
3. Slowly pressurize fuel tank to 3.3-4.3 psi (22.8-29.7
kPa). Check for air bubbles around fuel cap and flange.
4. Spray soap and water solution around two fittings on bot-
tom of fuel tank. Check for air bubbles around two fit-
tings.
5. Remove fuel cap from tank to make sure tank was pres-
surized.
6. Clean soap and water solution from fuel tank.
7. If bubbles were seen around fuel cap or flange, rework
gas cap or fuel tank and retest until no bubbles are
present when fuel tank is pressurized. If bubbles were
seen around fittings on bottom of fuel tank, tighten fit-
tings to specification. Reinstall fuel pump with new seals
if required. See 4.40 FUEL PUMP.
NOTE
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