Buell 2002 X1 Owner's Manual
Buell 2002 X1 Owner's Manual

Buell 2002 X1 Owner's Manual

Lubrication system
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LUBRICATION SYSTEM

CHECKING AND ADDING OIL
Check engine oil level in oil tank at least once every 500
miles (800 km). Check level more frequently if engine uses
more oil than normal or if vehicle is operated under harsh
conditions.

CHANGING OIL AND FILTER

After a new engine has run its first 500 miles (800 km) and at
5000 mile (8000 km) intervals or annually thereafter, com-
pletely drain oil tank of used oil. Refill with fresh oil. If vehicle
is driven extremely hard, used in competition or driven on
dusty roads, change engine oil at shorter intervals. Always
change oil filter when changing engine oil.
NOTE
See
1.6 ENGINE LUBRICATION SYSTEM
tion on checking oil level and changing oil and filter.
2002 Buell X1: Engine
WINTER LUBRICATION
Normal fuel combustion in a gasoline engine produces water
vapor and carbon dioxide along with other gases and particu-
lates. When first starting and warming an engine, some of the
water vapor that gets into the engine crankcase condenses to
form liquid water. If the engine is driven long enough to thor-
oughly warm the crankcase, most of this liquid water is again
vaporized and exhausted through the crankcase breather
system.
A moderately driven vehicle making short runs may not be
able to vacate water vapors allowing liquid water to accumu-
lates in the oil tank. This is especially true if the vehicle is
operated in cold weather. In freezing weather, an accumula-
tion of water in the engine oil may become slush or ice, which
can block oil lines and lead to severe engine damage. Water
remaining in the engine oil for long periods of time can form
an acidic sludge that is corrosive to metal engine parts and
for more informa-
causes accelerated wear of moving components.
In winter the oil change interval should be shorter than nor-
mal. The colder the weather, the shorter the recommended
oil change interval. A vehicle used only for short runs in cold
weather must have the engine oil drained frequently.
3.7
3-31

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Summary of Contents for Buell 2002 X1

  • Page 1: Lubrication System

    In winter the oil change interval should be shorter than nor- mal. The colder the weather, the shorter the recommended oil change interval. A vehicle used only for short runs in cold weather must have the engine oil drained frequently. 2002 Buell X1: Engine 3-31...
  • Page 2: Oil Hose Routing

    fitting (3) on the gearcase cover (4). b0743x3x b0344x3x Vent Hose Feed Hose Clamp Drain Hose Elbow Fitting Vent Hose Gearcase Cover Return Hose Figure 3-47. Vent Hose Connection (Typical) Figure 3-45. Oil Tank Hoses 3-32 2002 Buell X1: Engine...
  • Page 3: Oil Tank

    If seat is loose, it could shift during vehicle operation and startle the rider, causing Figure 3-49. Oil Tank loss of control. These events could result in death or serious injury. Install seat. See 2.40 SEAT. 2002 Buell X1: Engine 3-33...
  • Page 4: Oil Pressure Signal Light

    (69-117 kN/m ). At idle speed (950-1050 RPM), oil pres- ● Burned-out signal bulb. turned on (prior sure will vary from 7-12 psi (48-83 kN/m ● Dead battery (see NOTE above). to operating engine). 3-34 2002 Buell X1: Engine...
  • Page 5: Crankcase Breathing System

    (4). Hoses leading from the air cleaner bolts deposit the air inside the air cleaner’s snorkel. Push Rod Cover (2) Oil Drain Hole Umbrella Valve Breather Bolt Figure 3-52. Crankcase Breathing System, Typical Cylinder 2002 Buell X1: Engine 3-35...
  • Page 6 Oil is transferred to the teeth of all the cam gears lifter blocks and hydraulic lifters. Cross-drilled pas- through the gear meshing action. sages intersect the main feed galley and carry oil to each hydraulic lifter. 3-36 2002 Buell X1: Engine...
  • Page 7: Oil Pump

    Outer Gerotor between gerotor teeth Oil Inlet Oil Outlet Oil trapped between gerotor teeth Oil forced out Oil Inlet Oil Outlet Oil trapped between inner and outer gerotor teeth Outlet Figure 3-53. Principle of Gerotor Operation 2002 Buell X1: Engine 3-37...
  • Page 8 Cover Gerotor Feed Set Gerotor Separator Plate Gerotor Scavenge Set 10. Mounting Gasket 11. Gear Shaft 12. Body 13. Return Hose Elbow Connector 14. O-Ring 15. Thrust Washer 16. Retaining Ring Figure 3-55. Oil Pump 3-38 2002 Buell X1: Engine...
  • Page 9: Cleaning And Inspection

    11. Attach feed hose (3) and oil filter hose connection (5). 12. Attach clamp (6) and canister to hose. 13. Check engine oil level. Add oil to correct level if needed. 1.6 ENGINE LUBRICATION SYSTEM. 2002 Buell X1: Engine 3-39...
  • Page 10 Apply LOCTITE THREADLOCKER 243 (blue) to the ENGINE LUBRICATION SYSTEM. threads on that end of the filter adapter (1) which is installed into filter mount (4). Do not apply LOCTITE to adapter threads on filter element side. 3-40 2002 Buell X1: Engine...
  • Page 11: Hydraulic Lifters

    Accurately measure lifter bore inner diameter with a gauge. Clearance should be within 0.0008-0.0020 in. (0.0203-0.0508 mm). Fit a new lifter and/or replace crankcases if clear- ance exceeds SERVICE WEAR LIMIT of 0.0030 in. (0.076 mm). 2002 Buell X1: Engine 3-41...
  • Page 12: Installation

    Insert screw (8) with washer (10) through hole in retainer (6). Thread screw (8) into tapped hole in crankcase. Tighten screw to 15-18 ft-lbs (20-24 Nm). Install push rods and rocker covers. See 3.5 CYLINDER HEAD. 3-42 2002 Buell X1: Engine...
  • Page 13 Gearcase Cover Gasket 15. Rear Intake Cam Gear Bushing Front Exhaust Cam Gear 10. Right Crankcase Half 16. Pinion Shaft Bushing Pinion Gear 11. Nut 17. Gearcase Cover Figure 3-62. Gearcase and Valve Train Components 2002 Buell X1: Engine 3-43...
  • Page 14 fit in gearcase cover (17) and crankcase. Inspect each bushing against its corresponding cam gear shaft or pinion gear shaft. See Table 3-10. Figure 3-65. Use a BUSHING AND BEARING PULLER (Part No. HD-95760-69A) to remove bushings from gearcase cover and crankcase. 3-44 2002 Buell X1: Engine...
  • Page 15 See CAM BUSH- Figure 3-62. Using an arbor press, install each ING REAMING (GEARCASE COVER). bushing (7, 8 and 14) in its gearcase cover (17) bore so that bushing shoulder contacts cover boss. Orient each 2002 Buell X1: Engine 3-45...
  • Page 16: Bushing Reaming

    Although the original pinion shaft bushing is not “pinned,” the replacement bushing must be secured, from possible rotation within the cover bore, by installation of a dowel Figure 3-68. Drilling Dowel Pin Hole 3-46 2002 Buell X1: Engine...
  • Page 17: Cam Bushing Reaming (Crankcase)

    Thoroughly clean gearcase cover, removing all metal 12. Thoroughly clean gearcase cover, removing all metal chips/shavings. Blow out all oil passages using com- chips/shavings. Blow out all oil passages using com- pressed air. pressed air. 2002 Buell X1: Engine 3-47...
  • Page 18: Pinion Shaft Bushing Reaming (Gearcase Cover)

    (15-2) cam gear, the rear exhaust (15-1) and front Figure 3-72. Crankshaft Locking Tool (HD-43984) intake (15-3) cam gears must both be installed before the rear intake (15-2) cam gear is installed. 3-48 2002 Buell X1: Engine...
  • Page 19 Install cam position sensor in gearcase cover. See 4.30 CAM POSITION SENSOR AND ROTOR. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-74. Checking Cam Gear End Play 2002 Buell X1: Engine 3-49...
  • Page 20 (end play) in indicator readings is not 0.001- NUMBER 0.005 in. (0.025-0.127 mm). Choose shim from 24647-87 Blue Table 3-11. 24650-87 NOTE 24659-87 White/Grey Use a thinner shim for less end play; use a thicker shim for more end play. 24660-87 Green 3-50 2002 Buell X1: Engine...
  • Page 21 Upper Case Hex Socket Head Screw – 5/16-18 X 2-1/2 in. long (4) Bottom Case T40 TORX Bolt – 5/16-18 X 3/4 in. long (4) Muffler Mount Bolt – 3/8-16 X 5-1/2 in. long (2, with Washers and Locknuts) Figure 3-76. Crankcase Hardware (Typical) 2002 Buell X1: Engine 3-51...
  • Page 22 Retaining Ring Fitting Left Crankcase Half **Gearshaft Bearing Bearing Cup Right Crankcase Half Bearing Bearing Race Retaining Ring *Shim Outer Bearing Sprocket Shaft Bearing Spacer Snap Bearing Ring b0804a3x Oil Seal Figure 3-78. Crankcase Assembly 3-52 2002 Buell X1: Engine...
  • Page 23 Figure 3-79. Removing Sprocket Shaft Inner Timken Bearing (Typical) 2809 Figure 3-81. Install Claws on Snap Ring Crankshaft Bearing Tool (Part No HD-9457-101) b0807x3x Figure 3-80. Sprocket Shaft Outer Race Removal Figure 3-82. Remove Snap-Ring From Crankcase Bore 2002 Buell X1: Engine 3-53...
  • Page 24 (OD) of the inner race and the smallest measured inside diameter (ID) of the outer race (crankcase bushing). A running clearance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or flywheel assembly replacement and engine rebuild. 3-54 2002 Buell X1: Engine...
  • Page 25 (39.7459-39.7510 mm) Smallest Green 1.5650-1.5652 in. * Package color (39.7510-39.7561 mm) * Stamped number inside crankcase near race Figure 3-87. Bearing Identification SERVICE WEAR LIMIT: 1.5672 in. (39.8069 mm) Figure 3-85. Factory Outer Race Sizes 2002 Buell X1: Engine 3-55...
  • Page 26 With a 1.5651 in. (39.754 mm) ID outer race and a CAP (Part No. HD-95652-43A), and BEARING SEPARA- 1.2499 in. (31.747 mm) OD inner race, a blue bear- TOR (SNAP-ON TOOLS Stock No. CJ950). Apply heat to race to aid removal. ing is required. 3-56 2002 Buell X1: Engine...
  • Page 27: Lapping Engine Main Bearing Races

    fine lapping compound. 1.145" (29.08 mm) 1.135" (28.83 mm) 1.272" (32.31 mm) 1.262" (32.05 mm) Figure 3-89. Pinion Shaft Bearing Tools Crankcase Main Bearing Lapping Tool (Part No. HD-96710-40B) 3546a Figure 3-90. Lapping Pinion Shaft Main Bearing 2002 Buell X1: Engine 3-57...
  • Page 28 31.755- 31.760- 31.765- 31.770- 31.775- 31.780- 31.786- 3.791- 31.745 mm 31.750 mm 31.755 mm 31.760 mm 31.765 mm 31.770 mm 31.755 mm 31.780 mm 31.786 mm 31.791 mm 31.796 mm FACTORY COLOR CODE Green White 3-58 2002 Buell X1: Engine...
  • Page 29: Crankcase Halves

    (5) and into installer base (1). Press race into bore until firmly seated against retaining ring (3). NOTE Figure 3-93. Use SPROCKET SHAFT BEARING/SEAL INSTALLATION TOOL (Part No. HD-42579) to install sprocket shaft tapered roller bearings and seal. 2002 Buell X1: Engine 3-59...
  • Page 30 SPROCKET SHAFT SEAL/SPACER INSTALLER (Part No. HD-45206) onto sprocket shaft. Follow procedure in Step 8. Seal Rotate handle clockwise until the spacer makes contact with the bearing. Remove tool from sprocket shaft. Figure 3-95. Install Spacer in Seal 3-60 2002 Buell X1: Engine...
  • Page 31 Be sure to refill transmission to proper level with fresh lubri- cant. See 1.10 CLUTCH. 23. See 3.4 INSTALLING THE ENGINE and perform the applicable steps. Head Screw with Ball Inside Cylinder Stud Shoulder on Cylinder Stud Air Gun Figure 3-98. Cylinder Studs 2002 Buell X1: Engine 3-61...
  • Page 32 HOME NOTES 3-62 2002 Buell X1: Engine...

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