Air Cleaner - Buell 2002 X1 Handbook

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AIR CLEANER

REMOVAL
1. See Figure 4-108. Remove two screws (3) and washers
(2) from front and one bolt (27) and washer (2) from back
of air cleaner cover (1).
2. Remove air cleaner cover (1) and air filter (5).
3. Disconnect plug (29) from IAT (inlet air temperature) sen-
sor (11).
4. Remove hose (13) from snorkel (7).
5. Remove three screws (9) from snorkel plate (8). Remove
snorkel plate (8), snorkel (7) from support plate (24).
6. Remove three screws (17) and washers (18) and bolts
(22) and washers (2) securing air cleaner backing plate
(21) to wellnuts (25) in clamps (26).
7. Remove air cleaner backing plate (21).
a. Disconnect breather hoses (15,19) from fittings (23).
b. If necessary, pry grommet (20) from air cleaner
backing plate.
8. Remove IAT sensor (11) from top of snorkel (7).
9. Remove breather bolts (23) from support plate (24) and
remove support plate.
INSPECTION
1. See Figure 4-108. Inspect air cleaner. Check for dirt, torn
filter material and general condition. Replace if neces-
sary.
2. Inspect inside of backing plate and cover. Remove any
dirt or debris.
3. Inspect condition of backing plate grommet (20), If torn
or flattened, replace.
4. Inspect IAT sensor (11) and replace if faulty. Replace
grommet (12) if necessary.
INSTALLATION
1. See Figure 4-108. Install new gasket (10) on back of
support plate (24).
2. Apply HYLOMAR to threads of breather bolts. Install
support plate (24) with breather bolts (23) to cylinder
heads. Tighten breather bolts to 10-15 ft-lbs (14-20 Nm).
3. Install air cleaner backing plate (21).
a. Insert intake air temperature sensor plug (29)
through air cleaner backing plate (21) from back
side of air cleaner backing plate.
b. Position breather hoses (15, 19) on breather bolts
(23).
4. Install, but do not tighten, three screws (17) and washers
(18) to secure air cleaner backing plate (21) to wellnuts
(25) in clamps (26). Tighten screws to 3-5 ft-lbs (4-7 Nm)
after installing all three fasteners.
5. Install bolt (22) and washer (2) to secure backing plate to
vehicle frame.
6. Install IAT sensor (11) and grommet (12) into snorkel (7).
2002 Buell X1: Fuel System
7. If removed, position new gasket (10) in position on snor-
kel (7) flange.
8. Place snorkel (7) into position on backing plate (21)
ensuring inlet end is in gasket (6) properly.
9. Apply LOCTITE THREADLOCKER 243 (blue) to threads
of snorkel plate screws (9). Place snorkel plate (8) into
position and secure with screws (9). Tighten screws to 6-
8 ft-lbs (8-11 Nm).
10. Connect IAT sensor plug (29) to sensor (11).
11. Install hose (13) on snorkel (7).
12. Place a small piece of double sided tape at the upper-
center of the air filter foam gasket that fits against the
backing plate (21).
13. Position air filter (5) on air cleaner backing plate (21).
14. Install air cleaner cover (1).
a. Position air cleaner cover (1) over air cleaner back-
ing plate (21), making sure that air filter (5) is cor-
rectly positioned.
b. Install long bolt (27) and washer (2) first.
c. Align air cleaner cover (1) and secure with two
screws (3) and washers (2). Torque screws to 27-29
in lbs (3.1-3.3 Nm).
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