Buell 2002 X1 Handbook page 395

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ASSEMBLY/INSTALLATION
Depending on whether the rotor, the stator, or both the rotor
and stator were removed/disassembled, perform the applica-
ble procedures which follow:
1. See Figure 7-24. Feed stator wiring (4) with attached
grommet (3) into open grommet hole in left crankcase
half.
2. Apply a light coating of clean engine oil or chaincase
lubricant to grommet. Install grommet into hole in left
crankcase half.
CAUTION
Stator TORX screws contain a thread locking compound.
Do not reuse existing screws. Always use new screws
with the proper thread locking compound. Loss of torque
on TORX fasteners could result in alternator damage.
3. Position stator (1) on left crankcase half. Secure stator
using four new TORX screws (2). Tighten TORX screws
to 30-40 in-lbs (3-4 Nm).
4. Route stator wiring (4) in front of starter, behind gear-
case cover and outboard of oil pump.
NOTE
Temporarily attach a thin flexible "feed" or mechanic's wire to
the connector end of the stator wiring to assist in the routing
of the wiring.
7-22
3560
Pipe
Section
Sprocket
Figure 7-25. Pressing Rotor onto Sprocket
5. Connect alternator stator wiring to voltage regulator con-
nector [46]. Bundle excess wiring in front of oil pump.
Secure bundle to oil filter hose using a new cable strap.
6. See Figure 7-25. Attach rotor to sprocket.
a. Position rotor on sprocket. Align holes in sprocket
with holes in rotor.
b. Apply a drop of LOCTITE THREADLOCKER 243
(blue) to threads of each mounting bolt. Insert the
four mounting bolts through rotor and start bolts into
tapped holes in sprocket.
c. Position a section of pipe with an inside diameter
larger than the sprocket mounting hub over center of
rotor. Press rotor onto sprocket. Tighten bolts to 90-
110 in-lbs (10-12 Nm).
7. Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See
DRIVE/CLUTCH.
8. Install primary cover. See
1 1
WARNING WARNING
Always connect positive battery cable first. If the positive
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
9. Connect battery cables, positive cable first.
10. Test charging system. See
Rotor
6.5 PRIMARY
6.2 PRIMARY CHAIN.
7.6 CHARGING SYSTEM.
2002 Buell X1: Electrical