Buell 2002 X1 Handbook page 98

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INSTALLATION
NOTE
If roll pin protrudes beyond specification, check to make sure
it is fully seated. A channel lock pliers may be used to
squeeze/push roll pin in. Protect sideplate with a shop rag
when using pliers.
1. See Figure 2-84. Measure isolator roll pin protrusion on
both left and right isolator mounts with calipers or metal
rule. Roll pin should not protrude more than 0.120 in. (3
mm). If roll pin protrudes more than 0.120 in. (3 mm) file
or grind until within specification; 0.080-0.120 in. (2.032-
3.048 mm). Use care when filing to avoid creating sharp
edges.
2. See Figure 2-83. On left side of motorcycle, align locator
hole with roll pin and install rear isolator.
CAUTION
Use caution when installing isolator bolts. Make sure iso-
lator bolt hole is aligned with threaded hole in bearing
adjusting bolt to avoid cross-threading bolt.
3. See Figure 2-83. Loosely install isolator TORX bolt and
washer through rubber isolator into bearing adjusting
bolt. Do not tighten.
4. On right side plate, align locator hole with roll pin and
install rear isolator.
5. See Figure 2-85. Mark a horizontal line across the front
of each isolator with a light colored grease pencil or by
other non-permanent means.
6. Apply anti-seize to underside of isolator bolt head.
CAUTION
Use caution when installing isolator bolts. Make sure iso-
lator bolt hole is aligned with threaded hole in bearing
adjusting bolt to avoid cross-threading bolt.
7. Install isolator TORX bolt and washer through rubber iso-
lator into bearing adjustment bolt. Do not tighten.
8. See Figure 2-82. Install right side plate with three screws
and locknuts. Tighten side plate mount screws to 16-19
ft-lbs (22 -26 Nm).
CAUTION
See Figure 6. Observe marked line on rubber isolator
after isolator bolt is tightened. If marked line twists,
apply more LOCTITE ANTI-SEIZE to underside of isolator
bolt heads. Failure to comply will result in damage to
rubber isolators.
9. Tighten right and left isolator TORX bolts to 63-70 ft-lbs
(85-95 Nm).
10. Push rear upper Z bracket bolt until it protrudes from
mount block and install nut. Tighten rear upper Z-bracket
bolt to 8-10 ft-lbs (11-14 Nm).
11. Erase grease pencil marked lines from both isolators.
12. Apply LOCTITE 243 (Blue) to threads of two master cyl-
inder mounting screws.
13. Install rear brake master cylinder to right side plate with
two screws. Tighten screws to 8-10 ft-lbs (11-14 Nm).
2002 Buell X1: Chassis
0.080-0.120 in.
(2.032-3.048 mm)
Figure 2-84. Measuring Roll Pin Protrusion
b0674b2x
Rear Isolator
Marked
Line
Straight Line
(Correct)
OBSERVE MARKED LINE WHILE TIGHTENING
Figure 2-85. Checking Isolator Alignment
Pin
Twisted Line
(Incorrect)
2-51