Buell 2002 X1 Handbook page 341

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Primary Cover
1. Remove foreign material from magnetic drain plug.
Install plug and tighten to 14-30 ft-lbs (19-41 Nm).
2. Wipe gasket surface clean. Install new gasket on pri-
mary cover.
3. See Figure 6-4. Install primary cover and gasket onto left
crankcase half using mounting screws. Tighten screws to
100-120 in-lbs (11-14 Nm).
4. See Figure 6-1. Install new shifter lever oil seal (15).
5. Fit coupling (6) over cable end with rounded side
inboard, the ramp connector button outboard. With
retaining ring side of ramp assembly facing inward, place
hook of ramp (7) around coupling button and rotate
assembly counterclockwise until tang on inner ramp fits
in slot of primary cover.
6. Thread wellnut (5) on adjusting screw (14) until slot of
screw is accessible with a screwdriver. Fit wellnut hex
into recess of outer ramp and turn adjusting screw coun-
terclockwise.
7. Fill transmission to proper level with fresh lubricant. See
1.10 CLUTCH.
8. Adjust clutch. See 1.10
9. Adjust primary chain tension. See
CHAIN.
10. See Figure Figure 6-5.
LOCKER 243 (Blue) to shift lever mounting bolt.
11. Install shifter lever assembly with mounting bolt, washer
and plastic bushings and spacer. Do not tighten mount-
ing bolt.
12. Install rubber washer and upper shift lever assembly to
splined shaft.
13. Align clamp opening with mark made on splined shaft
during removal.
14. Apply LOCTITE THREADLOCKER 243 (Blue) to pinch
screw.
15. Install pinch screw to upper clamp.
16. Tighten pinch screw to 59-66 in-lbs (7-8 Nm).
17. Tighten mounting bolt to 27-29 ft-lbs (37-39 Nm).
18. Install muffler. See 2.28 EXHAUST
19. Connect negative battery cable to battery.
2002 Buell X1: Drive/Transmission
CLUTCH.
1.13 PRIMARY
Apply LOCTITE THREAD-
SYSTEM.
x0023a6x
2
1
2
1
3
1. 1/4-20 x 1-3/4 in. Bolt with Washers (7)
2. 1/4-20 x 2-1/4 in. Bolt with Washers (4)
3. 5/16-18 x 3-1/2 in. Bolt with Washers (2)
Figure 6-4. Install Primary Cover Bolts
Rubber
b0922x6x
Washer
Pinch Screw
59-66 in-lbs
(7-8 Nm)
Blue Loctite
Upper Clamp
Mounting Bolt
27-29 ft-lbs
(37-39 Nm)
Blue Loctite
Figure 6-5. Shifter Lever
1
2
1
Splined
Shaft
Plastic
Bushings (2)
Spacer
Washer
6-5