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Buell 2002 X1 Handbook

Buell 2002 X1 Handbook

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Service manual (462 pages)

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SUBJECT

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Care of Molded-in-Color Body Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Ceramic Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Brake Pads and Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.11 Drive Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.12 Drive Belt and Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.13 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.14 Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.15 Suspension Damping Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.16 Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.17 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.18 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.19 Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.20 Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.21 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.22 Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.23 Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.24 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.25 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE

PAGE NO.

1-1

1-5

1-11

1-12

1-13

1-15

1-17

1-20

1-21

1-22

1-24

1-26

1-28

1-29

1-30

1-31

1-32

1-34

1-35

1-36

1-37

1-39

1-40

1-41

1-42

1

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Summary of Contents for Buell 2002 X1

Page 1 MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fluid Requirements .
Page 3: General
(800 km), and at every 2500 mile (4000 km) interval thereaf- whenever necessary. Do not lift heavy parts by hand. A hoist ter, have a Buell dealer perform the service operations listed and adjustable lifting beam or sling are needed to remove Table 1-2.
Page 4: Repair And Replacement Procedures
Always use the proper tools and ﬁxtures for removing and installing bearings. Part Replacement Bearings do not usually need to be removed. Only remove bearings if necessary. Always replace worn or damaged parts with new parts. 2002 Buell X1: Maintenance...
Page 5: Part Protection
If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something lets go. Don’t use a screwdriver with rounded edges because it Never cock a wrench. will slip – redress with a ﬁle. 2002 Buell X1: Maintenance...
Page 6: Ratchets And Handles
Never cock any wrench or socket. Select only impact sockets for use with air or electric impact wrenches. Replace sockets showing cracks or wear. Keep sockets clean. Always use approved eye protection when using power or impact sockets. 2002 Buell X1: Maintenance...
Page 7: Fluid Requirements
= 1,000 milliliters (mL). Should you need to convert from U.S. descending order, are 20W-50, 15W-40 and 10W-40. At the units-of-measure to metric units-of-measure (or vice versa), ﬁrst opportunity, see a Buell dealer to change back to 100 refer to the following: percent Harley-Davidson oil.
Page 8 2002 Buell X1: Maintenance...
Page 9 2002 Buell X1: Maintenance...
Page 10 2002 Buell X1: Maintenance...
Page 11 2002 Buell X1: Maintenance...
Page 12 HOME NOTES 1-10 2002 Buell X1: Maintenance...
Page 13: Care Of Molded-In-Color Body Panels
NOTE maintenance instructions required for the molded-in-color Rain or water will remove Harley Gloss from body panels. body panels that are standard on your 2002 Buell Lightning Reapply Harley Gloss as described above to keep surfaces X1 motorcycle. looking their best.
Page 14: Ceramic Header
CARE AND MAINTENANCE The purpose of this section is to provide special care Washing instructions required for the blue ceramic header on the Buell Lightning X1 motorcycle. To wash blue ceramic header, follow the instructions below: Rinse surface with water.
Page 15 12.6 Clean cable connectors and battery terminals using a 12.3 wire brush or sandpaper. Remove any oxidation. 12.0 Inspect the battery screws, clamps and cables for break- 11.8 age, loose connections and corrosion. Clean clamps. 2002 Buell X1: Maintenance 1-13...
Page 16 Install battery strap locknut on threaded shaft. Tighten to 40 in-lbs (4.5 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Secure oxygen sensor connector with new cable straps. Install seat. See 2.40 SEAT. 1-14 2002 Buell X1: Maintenance...
Page 17: Engine Lubrication System
WEATHER 20W-50, 15W-40 and 10W-40. At the ﬁrst opportu- HARLEY-DAVIDSON VISCOSITY DAVIDSON AMBIENT STARTS TYPE nity, see a Buell dealer to change back to 100 per- RATING TEMP °F BELOW cent Harley-Davidson oil. 50° F ° H.D. Multi-Grade Below 40 Install ﬁller cap/dipstick.
Page 18 1000 RPM or above. 14. Check for oil leaks at oil ﬁlter and drain hose. 15. Check oil level. See CHECKING ENGINE OIL LEVEL. 1-16 2002 Buell X1: Maintenance...
Page 19: Brakes
Get medical attention for eyes. KEEP BRAKE Stand motorcycle upright. FLUID OUT OF THE REACH OF CHILDREN. Failure to comply could result in death or serious injury. Front brake caliper bleeder valve-Figure 1-8. 2002 Buell X1: Maintenance 1-17...
Page 20 Attach covers to master cylinder reservoirs. Tighten screws on front master cylinder reservoir to 9-13 in-lbs (1.0-1.5 Nm). Tighten cap on rear master cylinder reservoir securely. Remove cover from molded-in-color surfaces and right handlebar switches. 1-18 2002 Buell X1: Maintenance...
Page 21: Rear Brake Pedal
Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. Check rear brake pedal height.
Page 22: Brake Pads And Rotors
The brake rotor must be within the following speciﬁca- tions. If the brake rotor is suspected of being damaged, inspect rotor using the following measurements: Lateral Movement: 0.5 mm Radial Movement: 0.45 mm Rotational Movement: 0.39 mm 1-20 2002 Buell X1: Maintenance...
Page 23: Tires And Wheels
At every 10,000 mile (16,000 km) service interval. When storing or removing the motorcycle for the season. Check wheel bearings and axle spacers for wear and corro- sion. Excessive play or roughness indicates worn bearings. Replace bearings in sets only. 2002 Buell X1: Maintenance 1-21...
Page 24: Clutch
TORX screws with washers. Tighten in a crosswise pattern to 7-9 ft-lbs (10-12 Nm). Clutch Adjusting Screw Quad Ring Install mufﬂer. See 2.28 EXHAUST SYSTEM. Clutch Diaphragm Spring Fluid Level Figure 1-17. Fluid Level 1-22 2002 Buell X1: Maintenance...
Page 25 Install clutch inspection cover (2) using four TORX screws with washers (1). Tighten in a cross- wise pattern to 7-9 ft-lbs (10-12 Nm). Figure 1-20. Adjusting Clutch Free Play Check clutch cable free play. See Step 6 above. 2002 Buell X1: Maintenance 1-23...
Page 26: Drive Belt Deflection
Figure 1-22. Rear Axle Adjuster If belt requires adjustment, see Deﬂection Adjust- ment under 1.11 DRIVE BELT DEFLECTION. After adjusting deﬂection, check axle alignment. Install drive support arm, sprocket cover and chin fairing. 2.30 SPROCKET COVER. 1-24 2002 Buell X1: Maintenance...
Page 27 Tighten locknut (2) ﬂush against adjust- ing nut (3). Tighten axle nut (metric) to 66-73 ft-lbs (90-99 Nm). Axle Adjuster Bolt Verify that belt deﬂection is correct. Locknut Adjusting Nut Figure 1-24. Axle Adjuster Bolt, Right Side Shown 2002 Buell X1: Maintenance 1-25...
Page 28: Drive Belt And Sprocket
This condition will result in belt failure and indicates worn transmission sprocket teeth. Replace belt and transmis- sion sprocket. Signs of puncture or cracking at the base of the belt teeth. Replace belt if either condition exists. 1-26 2002 Buell X1: Maintenance...
Page 29 OK to run, but monitor condition Fuzzy edge cord OK to run, but monitor condition Hook wear Replace belt Stone damage Replace belt if damage is on the edge Bevel wear (outboard edge only) OK to run, but monitor condition 2002 Buell X1: Maintenance 1-27...
Page 30: Primary Chain
Loosen locknut (1). Turn adjusting screw (2): Clockwise (inward) to reduce free play. Adjusting Screw Counterclockwise (outward) to increase free play. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Figure 1-28. Measuring Primary Chain Adjustment 1-28 2002 Buell X1: Maintenance...
Page 31: Preload Adjustment
90 degrees to the torque wrench. Wipe excess grease off of shock absorber. NOTE When preload is increased, both compression and rebound damping should be increased. If preload is decreased, both compression and rebound damping should be decreased. 2002 Buell X1: Maintenance 1-29...
Page 32: Suspension Damping Adjustments
Recommended Damping Settings (X1) Rebound Adjuster SOLO SOLO SOLO Slotted Dial SETTINGS 2 UP (STD) (FIRM) (SOFT) Figure 1-33. Rear Shock Compression and Rebound Front Rebound Damping Adjustments Front 1.25 Compression Rear Rebound Rear 2.25 0.25 0.75 Compression 1-30 2002 Buell X1: Maintenance...
Page 33: Front Fork
Left and right forks must contain equal amounts of fork oil. Standard Oil Level 3.15 in. 80 mm Assemble and install forks. See 2.16 FRONT FORK. Maximum Oil Level 4.333 in. 110 mm Minimum Oil Level 2.36 in. 60 mm 2002 Buell X1: Maintenance 1-31...
Page 34: Steering Head Bearings
(16,000 km) thereafter, lubricate the steering head bearings with WHEEL BEARING GREASE (Part No. 99855-89). 4.5-6.5 lbs 2.17 FORK STEM AND BRACKET ASSEMBLY for lubri- (2.0-2.9 kg) cation procedure. b0745a1x Figure 1-38. Checking Steering Head Bearings 1-32 2002 Buell X1: Maintenance...
Page 35 Fork Stem Bolt Upper Triple Clamp Dust Shield (2) Roller Bearing (2) Bearing Cup (2) Lower Triple Clamp Lower Triple Clamp Pinch Screws (2) Screw Upper Triple Clamp Pinch Screws (2) Figure 1-39. Steering Head Assembly 2002 Buell X1: Maintenance 1-33...
Page 36: Spark Plugs
If the plugs cannot be cleaned, replace with No. 10R12 connected to coil and spark plugs. spark plugs. 10. Install left side air scoop. See 2.36 AIR SCOOP. Check electrode gap with a wire-type feeler gauge. Gap should be 0.038-0.043 in. (0.97-1.09 mm). 1-34 2002 Buell X1: Maintenance...
Page 37: Air Cleaner Filter
(3). Make sure air ﬁlter and trim are correctly posi- tioned. Install long screw and nylon washer (2). Tighten to 27-29 in-lbs (3.1-3.3 Nm). Install two screws and nylon washers (1) to secure air cleaner cover. Tighten to 27-29 in-lbs (3.1-3.3 Nm). 2002 Buell X1: Maintenance 1-35...
Page 38: Throttle Cables
Recheck engine slow idle speed; adjust if required. Regular idle speed is 850-1050 RPM. Set idle speed using 11. Install air cleaner assembly. See 4.42 AIR CLEANER. idle adjustment screw (4) shown in Figure 1-45. 1-36 2002 Buell X1: Maintenance...
Page 39: Ignition Timing
Attach female gray connector on BREAKOUT BOX (Part No. HD-42682) to electronic control module. Attach male gray connector on BREAKOUT BOX to wiring harness. Connect red (+) lead on voltmeter to Pin 3 on gray side of BREAKOUT BOX. 2002 Buell X1: Maintenance 1-37...
Page 40 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 10. Install seat. See 2.40 SEAT. 1-38 2002 Buell X1: Maintenance...
Page 41: Handlebars
Attach windscreen with four screws and rubber washers. Check steering motion range to both fork stops. Handle- bars should not make contact with the front forks or fuel tank cover. If handlebar needs further adjustment, repeat adjustment beginning with Step 1. 2002 Buell X1: Maintenance 1-39...
Page 42 Tilt headlamp up or down to aim it in relation to the horizontal line. At the same time, turn headlamp right or left to direct light beam straight ahead. Tighten both adjuster screws (metric) to 5-7 ft-lbs (7-10 Nm). 1-40 2002 Buell X1: Maintenance...
Page 43: Electrical System
Shifter pawl improperly adjusted. Smokes Excessively Shifter engaging parts (inside transmission) badly worn Piston rings badly worn or broken. and rounded. Valve stem seals worn or damaged. Shifter forks bent. Valve guides worn. Damaged gears. 2002 Buell X1: Maintenance 1-43...
Page 44: Storage
REMOVAL FROM STORAGE varnish in the fuel system. This work should be performed by your local Buell dealer fol- lowing Service Manual procedures. WARNING WARNING Fill fuel tank and add a gasoline stabilizer.
Page 45: Troubleshooting
20. TPS/fast idle screw not set properly. See dealer. 20. Inoperative fuel injector. See dealer. 21. No output from CMP sensor. See dealer. 21. Obstructed fuel tank vent valve or pinched vent tube. 22. Inoperative fuel pump. See dealer. See dealer. 1-42 2002 Buell X1: Maintenance...
Page 46 Brake pads badly worn to minimum lining thickness. Brake rotor badly worn or warped. Brake pads dragging or excessive braking (brake fades due to heat buildup). Insufﬁcient brake pedal or hand lever free play (brake drags). 1-44 2002 Buell X1: Maintenance...
Page 47: Table Of Contents
Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 48 31 -34 Nm LOCTITE THREADLOCKER 271 (red), page 2-69 Footrest Mount Bolts, Passenger 13-16 ft-lbs 18-22 Nm LOCTITE THREADLOCKER 243 (blue), page 2-72 Footrest Mounting Bolt 10-15 ft-lbs 14 -20 Nm LOCTITE THREADLOCKER 243 (blue), page 2-69 2002 Buell X1: Chassis...
Page 49 57-61 Nm LOCTITE ANTI-SEIZE, page 2-68 Rear Axle Nut 66-73 ft-lbs 90-99 Nm metric, page 2-48 Rear Axle Nut 66-73 ft-lbs 90-99 Nm metric, page 2-6 Rear Brake Caliper Banjo Bolt 16-20 ft-lbs 22-27 Nm page 2-35 2002 Buell X1: Chassis...
Page 50 Tail Section Bolts 9-11 ft-lbs 12-15 Nm page 2-80 Tie Bar Bolts 30-33 ft-lbs 41-45 Nm page 2-51 Turn Signal Nuts 96-120 in-lbs 11-14 Nm metric, page 2-80 Valve Stem Nut 42-44 in-lbs 4.7-5.0 Nm page 2-16 2002 Buell X1: Chassis...
Page 51: Tire Specifications
& POSITION RIM SIZE HOLE DIAMETER TIRE SIZE 17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17 D207F 17 in. – Rear MT 5.5 x 17.0 DOT 0.33 in. 170/60 ZR17 D207 2002 Buell X1: Chassis...
Page 52: Vehicle Identification Number
An abbreviated V.I.N. is stamped on the front left side of the crankcase. NOTE Figure 2-3. Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle. Figure 2-2. Abbreviated V.I.N. Location Manufacturer: Buell Motorcycle Company Type Designation-Lightning X1...
Page 53 Correct adjustment and replace pitted or worn bearings. See 1.17 STEER- ING HEAD BEARINGS. Damper tubes. Check for leaks. See 2.16 FRONT FORK. Shock absorbers. Check damping action and mounts. See 1.15 SUSPENSION DAMPING ADJUSTMENTS. Swingarm bearings. Check for looseness. See 2.19 SWINGARM. 2002 Buell X1: Chassis...
Page 54 In some cases small punctures in the tread area may be repaired from within the demounted tire by your Buell dealer. Speed should not exceed 50 mph (80 km/h) for the ﬁrst 24 hours after repair and the repaired tire should NEVER be used over 80 mph (1340 km/h).
Page 55: Front Wheel
Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Fail- ure to install brake pads as a set could result in death or serious injury. Inspect brake rotor and pads. See 1.8 BRAKE PADS ROTORS. 2002 Buell X1: Chassis...
Page 56 Install tire, if removed. See TIRES. TORX screws (12). Tighten TORX screws in criss- Verify that wheel and tire are true. See 2.7 CHECKING cross pattern to 20-22 ft-lbs (27-30 Nm). CAST RIM RUNOUT. Balance tire. See 2.8 TIRES, Adjustment. 2002 Buell X1: Chassis...
Page 57 While holding axle stationary, tighten axle nut (4) (metric) to 48-53 ft-lbs (65-72 Nm). Tighten the four front axle pinch screws (2) (metric) to 13-15 ft-lbs (18-20 Nm). Install front brake caliper. See 2.11 FRONT BRAKE CALIPER. 2-10 2002 Buell X1: Chassis...
Page 58: Rear Wheel
Spacer Sleeve Wheel Valve Stem Wheel Weight 10. Bearings (2) 11. Right Axle Spacer 12. Washer 13. Lockwasher 14. Axle Nut (metric) 15. Belt Sprocket 16. Washer (5) 17. Bolt (5) Figure 2-9. Rear Wheel 2002 Buell X1: Chassis 2-11...
Page 59: Cleaning And Inspection
(1) (metric). Fasten rotor to wheel hub using screws. Tighten to 35-40 ft-lbs (48-54 Nm). NOTE: PM Wheel option uses a nut. NOTE P/M wheels use a nut (not shown) with each screw (1). 2-12 2002 Buell X1: Chassis...
Page 60 1.11 DRIVE BELT DEFLECTION. Tighten rear axle nut (14) (metric) to 66-73 ft-lbs (90- 99 Nm). 7042 Axle Axle Nut (metric) Lockwasher Washer Axle Carrier Right Side of Swingarm Spacer Figure 2-12. Axle, Right Side 2002 Buell X1: Chassis 2-13...
Page 61: Checking Cast Rim Runout
Wheel Truing and Balancing RUNOUT RUNOUT Stand (Part No. HD-99500-80) Cast 0.040 in. 0.030 in. (1.02 mm) (0.76 mm) Aluminum P/M 0.020 in. 0.020 in. (0.51 mm) (0.51 mm) Gauge Rod Figure 2-14. Checking Cast Rim Radial Runout 2-14 2002 Buell X1: Chassis...
Page 62 A bead breaker machine simplifies tire Dunlop front and rear tires for Buell motorcycles are removal not the same. They are not interchangeable. Use front tire ONLY for a front tire. DO NOT put a rear tire Figure 2-15.
Page 63 (2.03 mm). If runout is more than 0.080 in. (2.03 mm), remove tire from rim. Check rim bead side runout. See 2.7 CHECKING CAST RUNOUT. Replace rims not meeting speciﬁcations. Install tire and check again for tire tread lateral runout. 2-16 2002 Buell X1: Chassis...
Page 64: Wheel Balancing
BONDER 420 to adhesive side of weight. Place weight on ﬂat surface of wheel rim. Press weight ﬁrmly in place and hold for ten seconds. Allow eight hours for adhesive to cure completely before using wheel. 2002 Buell X1: Chassis 2-17...
Page 65 To prevent death or serious Use only new black banjo washers (See Parts Catalog for injury, Buell recommends that all brake repairs be per- Part No.) with D.O.T. 4 brake ﬂuid. Earlier silver banjo formed by a Buell dealer or other qualiﬁed technician.
Page 66 Replace pads. brake pads. Brake pads drag on rotor – Cup in master cylinder not uncovering Inspect master cylinder. will not retract. relief port. Rear brake pedal linkage out of Adjust linkage. adjustment. 2002 Buell X1: Chassis 2-19...
Page 67: Front Brake Master Cylinder
Compress piston (2) and remove rub- Screw ber boot (1). Depress piston assembly and remove internal snap ring Figure 2-22. Front Master Cylinder (3). Discard snap ring. Figure 2-25. Remove piston assembly (1-4) from front master cylinder. 2-20 2002 Buell X1: Chassis...
Page 68 Attach front brake lamp switch with screw (8). Piston Tighten to 7-13 in-lbs (1-2 Nm). Boot Snap Ring Test switch action. Tang on switch must release when hand lever is moved. Figure 2-25. Piston Assembly 2002 Buell X1: Chassis 2-21...
Page 69 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed technician. Bleed brake system. See BRAKES.
Page 70: Front Brake Caliper
Pry O-rings (6) out of their respective grooves on each side of caliper. Discard O-rings. Check bleeder valve (4) (metric). Remove and replace if damaged. Pad Hanger Pin (metric) Pad Spring Screws (4) (metric) Figure 2-30. Pad Spring (Typical) 2002 Buell X1: Chassis 2-23...
Page 71 D.O.T. 4 ﬂuid and will not seal properly over time. Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury. 2-24 2002 Buell X1: Chassis...
Page 72 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious Master Cylinder Cover injury, Buell recommends that all brake repairs be per- Screws (2) formed by a Buell dealer or other qualiﬁed mechanic.
Page 73: Front Brake Line
To avoid leakage, verify that gaskets, banjo bolt, hydrau- lic brake line and caliper bore are completely clean. Figure 2-36. Connect brake line to caliper using two new banjo washers (7) and banjo bolt (6). Loosely install bolt into caliper. 2-26 2002 Buell X1: Chassis...
Page 74 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. Install bleeder valve if removed. Reﬁll master cylinder and bleed brakes.
Page 75: Rear Brake Master Cylinder
10. Locknut Depress rod assembly (3) and remove internal snap ring 11. Turnbuckle (2). Discard snap ring. 12. Screw Remove piston assembly (4) from master cylinder body. 13. Remote Reservoir Figure 2-39. Rear Master Cylinder Assembly 2-28 2002 Buell X1: Chassis...
Page 76 Figure 2-39. Connect brake line (3) to master cylin- der (4) with two new banjo washers (2) and banjo bolt (1) (metric). Tighten to 16-20 ft-lbs (22-27 Nm). 2002 Buell X1: Chassis 2-29...
Page 77 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. Add brake ﬂuid and bleed brake system. See BRAKES.
Page 78: Rear Brake Caliper
Wipe dry with a clean, lint free cloth. Blow ROTORS. out drilled passages and bore with a clean air supply. Do not use a wire or similar instrument to clean drilled pas- sages. 2002 Buell X1: Chassis 2-31...
Page 79 Install large caliper screw (7) (metric). Tighten to 18- 22 ft-lbs (24-30 Nm) Install small caliper screw (6) (metric). Tighten to 14.5-18 ft-lbs (20-24 Nm). Brake Caliper Piston Remover Adaptor Piston Figure 2-47. Removing Rear Brake Caliper Piston 2-32 2002 Buell X1: Chassis...
Page 80 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. Depress rear brake pedal several times to set brake pads to proper operating position within caliper.
Page 81: Rear Brake Line And Switch
NOTE If replacing rear brake light switch, place brake line in vise gently (securing hexagonal rear brake light switch ﬁtting) to prevent bending brake line while removing or installing rear brake lamp switch. 2-34 2002 Buell X1: Chassis...
Page 82 16-20 ft-lbs (22-27 Nm). NOTE: Removing inner fender TORX screw and plastic washer will assist in tightening banjo bolt. If TORX screw and plastic washer are removed, tighten to 72-96 in-lbs (8-11 Nm) when installing. 2002 Buell X1: Chassis 2-35...
Page 83 If brakes are not operating properly or braking efﬁciency is poor, testing at high speeds could result in death or serious injury. 20. Test ride motorcycle and check for proper brake opera- tion. 2-36 2002 Buell X1: Chassis...
Page 84 Remove the fork oil by pumping the fork leg and rod 8-10 times until the rod moves freely. Clamp the axle holder in a vise with soft jaws or use a shop towel. Remove the center bolt (19) (metric) and the special washer (18). 2002 Buell X1: Chassis 2-37...
Page 85 11. Oil Seal 12. Stopper Ring 13. Dust Seal 14. Damper Assembly 15. Centering Plate 16. Slide Bushing 17. Slide Pipe 18. Special Washer 19. Center Bolt 20. Mounting Bolt b0652x2x Figure 2-57. Front Fork Assembly 2-38 2002 Buell X1: Chassis...
Page 86 Figure 2-60. Slide Pipe Protection Install the seal spacer (2), the guide bushing (1) and the slide bushing (6) onto the slide pipe. Coat the slide bushing (6) and the guide bushing (1) with fork oil. 2002 Buell X1: Chassis 2-39...
Page 87 Install fork bolt. Tighten to 22-29 ft-lbs (30-39 Nm). Figure 2-63. Spring Installation 20. Tighten rebound adjuster against the fork bolt. 21. Set rebound and compression adjusters to factory posi- tions. See 1.15 SUSPENSION DAMPING ADJUST- MENTS. 2-40 2002 Buell X1: Chassis...
Page 88 Install front brake caliper. See 2.11 FRONT BRAKE CALIPER. Align headlamp. See 1.23 HEADLAMP. Adjust front forks to rider preferences. See 1.15 SUS- 2.0 in. PENSION DAMPING ADJUSTMENTS. (50.8 mm) Figure 2-65. Aligning Front Forks 2002 Buell X1: Chassis 2-41...
Page 89: Fork Stem And Bracket Assembly
Replace damaged 10. Set Screw bearings (4) as a set (3, 4 and 5). 11. Screw Check the fork stem and lower triple clamp (6) for dam- age. Replace if necessary. Figure 2-66. Fork Stem 2-42 2002 Buell X1: Chassis...
Page 90 See Fork Stem Clamp Screw 1.17 STEERING HEAD BEARINGS. Figure 2-68. Fork Stem Clamp Screw Make sure the fork stem turns freely, then tighten the fork stem clamp screw (3). 2002 Buell X1: Chassis 2-43...
Page 91: Steering Head Lock
Turn handlebars all the way to the left. Insert ignition key in lock. Turn key clockwise while pushing in. Remove key and verify that steering head is locked. Unlock steering head by inserting key and turning key counterclockwise. 2-44 2002 Buell X1: Chassis...
Page 92 16. Using ﬂoor hoist, raise frame enough to remove both rubber isolators (6) from frame mounted pins. 17. Loosen swingarm pinch screw (4) on right side. 18. Remove threaded rod (1) from between bearing adjust- ing bolts (2, 3). 2002 Buell X1: Chassis 2-45...
Page 93 Carefully press roller bearing cups from component is damaged. swingarm using STEERING HEAD BEARING RACE Check that swingarm is not bent or twisted. Replace if REMOVER (Part No. HD-39301A) and UNIVERSAL damaged. DRIVER HANDLE (Part No. HD-33416). 2-46 2002 Buell X1: Chassis...
Page 94 Tighten rod to an initial torque of 10-13 ft-lbs (14-18 Nm). Check swingarm preload using a scale as shown in Fig- ure 2-78. Preload should be 3.0-3.75 lbs (1.36-1.70 kg). If preload does not meet speciﬁcations, tighten or loosen threaded rod and recheck. 2002 Buell X1: Chassis 2-47...
Page 95 Tighten axle nut (metric) to 66-73 ft-lbs (90-99 Nm). Ver- ify that belt deﬂection is correct. Lower motorcycle onto b0633xsb lift. Figure 2-80. Belt Deﬂection 6852 Axle Adjuster Bolt Locknut Figure 2-81. Axle Adjuster Bolt, Right Side Shown 2-48 2002 Buell X1: Chassis...
Page 96 23. Check rear brake operation. 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. 19. Attach both battery cables, positive cable ﬁrst. 2002 Buell X1: Chassis 2-49...
Page 97: Rear Isolators
13. Remove right side isolator bolt, washer and isolator. 14. Remove left side isolator bolt and washer. . 15. Pull frame to left and remove isolator from 6 or 7 o’clock position. 2-50 2002 Buell X1: Chassis...
Page 98 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 2-51...
Page 99 Failure to have proper brake lamp operation could result in death or serious injury. 20. Turn ignition key ON, depress rear brake pedal and check for proper brake light operation. 21. Test ride motorcycle at low speed and check for proper operation. 2-52 2002 Buell X1: Chassis...
Page 100: Rear Shock Absorber
12. Install chin fairing. See 2.34 CHIN FAIRING. 13. Check rear shock preload. See 1.14 PRELOAD ADJUSTMENT. 2002 Buell X1: Chassis 2-53...
Page 101 Reservoir Mount Block Rear Reservoir Clamp Nylon Locknut (2) Washers Front Reservoir Clamp Washers (3) Metal Locknut (2) 30-33 ft-lbs (41-45 Nm) Front Shock Mount 40-45 ft-lbs (54-61 Nm) Figure 2-87. Rear Shock Absorber 2-54 2002 Buell X1: Chassis...
Page 102: Suspension Theory
Evaluating and changing the rebound and compression damping is a very subjective process. Many variables affect motorcycle handling under different circumstances. Approach all changes carefully and consult Table 2-9. b0558xox Compression Adjuster Figure 2-90. Preload and Compression Damping Adjustment 2002 Buell X1: Chassis 2-55...
Page 103: Spring Preload
Front Rebound travel for the rider’s weight and the motorcycle’s cargo load. Front 1.25 Make this adjustment before the motorcycle is ridden any dis- Compression tance. Your Buell dealer can assist you if necessary. Rear Rebound Rear ADJUSTMENTS 2.25 0.25 0.75...
Page 104 Not absorbing bumps. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings. Lack of tire feedback. Increase compression damping. Tire slides. Decrease compression damping. 2002 Buell X1: Chassis 2-57...
Page 105 FRONT FORK REAR SHOCK REAR SHOCK DATE RESULTS REBOUND COMPRESSION REBOUND COMPRESSION Max damping Max damping Max damping Max damping Factory recommended minus 0.5 turn minus 1.25 turns minus 1.5 turn minus 2.25 turns settings. 2-58 2002 Buell X1: Chassis...
Page 106: Throttle Control
Tighten screws to 12-17 in-lbs (1-2 Nm). Screw (short, top) Cable Adjusters (2) Idle Control Cable Throttle Control Cable with Molded End Front Housing Screw (Long, Bottom) Ferrules Cable Wheel Rear Housing 10. Locating Pin Figure 2-92. Cable Connections 2002 Buell X1: Chassis 2-59...
Page 107 Attach throttle cable clamp to fer- rules with screw (arrow on clamp points up). Install air cleaner assembly. See 4.42 AIR CLEANER. Figure 2-95. Throttle Body Routing 8204 Throttle Cable Clamps Screw Arrow (Up) Figure 2-96. Throttle Cable Clamps 2-60 2002 Buell X1: Chassis...
Page 108: Clutch Control
Outer Ramp Ball (3) O-Ring Cable End Fitting 10. Clutch Cable End 11. Primary Cover 12. Clutch Adjusting Screw Assembly 13. Retaining Ring 14. Quad Ring 15. Inner Ramp 16. Coupling Figure 2-97. Clutch Release Mechanism 2002 Buell X1: Chassis 2-61...
Page 109 See 1.10 CLUTCH. ple clamp. Continue to right side, down between right fork leg and steering neck. Route cable between right side of the steering head and left of front brake line. 2-62 2002 Buell X1: Chassis...
Page 110: Instrument Support
Figure 2-101. Instrument Support Wiring Insert indicator light housing into bezel. Secure with four catches. Figure 2-100. Install both instruments. See 7.17 SPEEDOMETER 7.18 TACHOMETER. Attach windscreen using four screws and washers. 2002 Buell X1: Chassis 2-63...
Page 111 Wipe off excess adhesive with a rag. Install front brake master cylinder. See 2.10 FRONT BRAKE MASTER CYLINDER. Attach windscreen using four screws and washers. Check steering motion range to both fork stops. See 1.22 HANDLEBARS. 2-64 2002 Buell X1: Chassis...
Page 112: Exhaust System
Slide exhaust header from behind frame. Figure 2-107. Remove exhaust header clamps (22), Jack exhaust clamp retaining rings (23) and exhaust port gas- kets (24) from exhaust header. Figure 2-106. Supporting Motorcycle with Jack 2002 Buell X1: Chassis 2-65...
Page 113 Mount Bracket Washer (2) Spacer Washers (2) Grade 8 Bolt 22-24 ft-lbs Mount Metal (30-33 Nm) Tabs Locknuts (2) 20-22 ft-lbs (27-30 Nm) Muffler Metal Locknut Voltage Regulator Mounting Bracket Voltage Regulator Figure 2-107. Exhaust System 2-66 2002 Buell X1: Chassis...
Page 114 Install new exhaust port gaskets and exhaust clamp retaining rings. Slide exhaust header clamps over ends of exhaust header. Figure 2-108. Slide exhaust header under frame by positioning as shown, threading oxygen sensor wire under frame. 2002 Buell X1: Chassis 2-67...
Page 115 Tighten sensor to 42-45 ft-lbs (57-61 Nm). Attach oxygen sensor connector [137]. Secure wiring and sensor with new cable ties. Tighten mufﬂer clamp hardware to 40-45 ft-lbs (54-61 Nm). Install chin fairing. See 2.34 CHIN FAIRING. 2-68 2002 Buell X1: Chassis...
Page 116 Figure 2-111. Footrests spring inboard. Install pin (3) through spring (4), mount (6) and foot- rest (5). Install washer (2) and retaining ring (1) to pin (3). Make sure retaining ring engages groove in pin. 2002 Buell X1: Chassis 2-69...
Page 117: Sprocket Cover
Tighten nut to 30-35 ft-lbs (41-47 Nm). Cover Screw 48-72 in-lbs Spacer (5-9 Nm) Blue Loctite Screws (2) Swingarm/Drive 20-25 ft-lbs Support (27-34 Nm) Locknut Red Loctite 30-35 ft-lbs (41-47 Nm) Figure 2-113. Sprocket Cover 2-70 2002 Buell X1: Chassis...
Page 118: Front Fender
Tighten lower fender mounting screws (8) (metric) to 10-15 in-lbs (1-2 Nm). Front Fender Reﬂector (2) (U.S. Models) Screw (2) Washer (2) Wire Guide (2) Plastic Spacer (4) Locknut (2) Screw (2) (metric) Nylon Washer (2) Figure 2-114. Front Fender 2002 Buell X1: Chassis 2-71...
Page 119: Rear Fender
Figure 2-115. Rear Fender With Brake Line (Left Side) Attach footrest mounts on both sides. Tighten bolts to 13- 16 ft-lbs (18-22 Nm). b0608x2x Screw (2) Washer (2) Fender Wellnut (2) Screw Washer Wellnut Screw Washer Figure 2-116. Rear Fender 2-72 2002 Buell X1: Chassis...
Page 120: Belt Guards
Lower Belt Guard Stone Guard Wellnut (2) Figure 2-117. Belt Guard and Stone Guard Installation b0729x2x Swingarm Screw (2) Washer (2) Lower Belt Guard Stone Guard Wellnut (2) Figure 2-118. Stone Guard and Belt Guard Mounting 2002 Buell X1: Chassis 2-73...
Page 121: Chin Fairing
Check for clutch cable contact. If contact occurs, adjust clutch cable clamp. Bolt 8303 Washer Rubber Washer Chin Fairing Figure 2-121. Chin Fairing, Right Side Bolt and Washer Chin Fairing Clutch Cable Shift Lever Bolt, and Washer Figure 2-119. Chin Fairing, Left Side 2-74 2002 Buell X1: Chassis...
Page 122: Fuel Tank Cover
Install seat. See 2.40 SEAT. Screw (2) Washer (2) Fuel Tank Cover Wellnut (2) Figure 2-123. Fuel Tank Cover 2002 Buell X1: Chassis 2-75...
Page 123: Air Scoop
Install screw and washer into wellnut at bottom of scoop. Figure 2-125. Install screw, washer, and nut to 6978 attach air scoop (1) to clamp (3). Air Scoop Clamp Screw and Washer Figure 2-125. Air Scoop Clamp 2-76 2002 Buell X1: Chassis...
Page 124 (2) with screws and washers (1). 6885 Figure 2-128. Attach data link connector [91A] to trunk. License Plate Bracket Screw and Washer (2) Figure 2-127. License Plate Bracket 7987 Data Link [91A] Figure 2-128. Data Link Location 2002 Buell X1: Chassis 2-77...
Page 125: Tail Section
(2). Pull the three wires from back of tail lamp. Tilt license plate bracket (3) forward to remove. Figure 2-132. Remove two allen bolts (15), washers (3) and nuts (10) to detach seat lock (11) from tail sec- tion (14). 2-78 2002 Buell X1: Chassis...
Page 126 16. Seat Screw (4) 17. Bracket, Electronic Control Nut (4) 18. Nut (4) Washer (6) 19. Washer (4) Bracket, License Plate 20. Screw (4) 10. Nut (2) 11. Lock Assembly b0664x2x Figure 2-132. Tail Section 2002 Buell X1: Chassis 2-79...
Page 127 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 11. Install seat. See 2.40 SEAT. 2-80 2002 Buell X1: Chassis...
Page 128 If removed, install both windscreen brackets. See 2.16 FRONT FORK. Align windscreen on right and left brackets. Figure 2-134. Install two screws and nylon washers on each side. Tighten securely. Figure 2-134. Windscreen, Right Side 2002 Buell X1: Chassis 2-81...
Page 129 Turn ignition key and remove from seat lock. ATTACHMENT POINTS CAUTION Helmet hook will not prevent helmet theft. See your Buell dealer for helmet locking solutions. Figure 2-136. Two metal hooks, cables and locktabs on the tail section serve as helmet holders. To store helmet, place cable through helmet D-ring.
Page 130: Side Stand
Remove REAR WHEEL SUPPORT STAND (Part No. B- Figure 2-139. Side Stand Dragger Wear Limit 41174). With side stand retracted, there should be 0.5 in. (12.7 mm) clearance between side stand and swingarm at the closest point of contact. 2002 Buell X1: Chassis 2-83...
Page 131 HOME NOTES 2-84 2002 Buell X1: Chassis...
Page 132 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 133: Specifications
2.105 in. (min) 53.467 mm (min) 1.751-1.848 in. 72-92 lbs 33-42 kg (closed) Intake 1.286-1.383 in. 183-207 lbs 83-94 kg (open) 1.751-1.848 in. 72-92 lbs 33-42 kg (closed) Exhaust 1.332-1.429 in. 171-195 lbs 78-88 kg (open) 2002 Buell X1: Engine...
Page 134 89.0270 mm ± 0.0002 in. 0.010 OS 3.507 in. 89.078 mm 3.5100 in. 89.1540 mm 0.020 OS 3.517 in. 89.332 mm 3.5200 in. 89.4080 mm OS=over size 0.030 OS 3.527 in. 89.586 mm 3.5300 in. 89.6620 mm 2002 Buell X1: Engine...
Page 135 Outer race diameter in 39.7408-39.7561 mm 1.5646-1.5652 in. 1.5672 in. (max) 39.8069 mm (max) right crankcase 0.00305-0.02235 mm Bearing running clearance 0.00012-0.00088 in. Fit in cover bushing 0.0023-0.0043 in. 0.0584-0.1092 mm 0.0050 in. 0.1270 mm (loose) 2002 Buell X1: Engine...
Page 136: Torque Values
3-22 Swingarm Mount Block Bolts, Lower 68-75 ft-lbs 92-102 Nm page 3-10 Swingarm Mount Block Bolts, Upper 41-45 ft-lbs 56-61 Nm page 3-10 Tie Bar Bolts 30-33 ft-lbs 41-45 Nm page 3-10 2002 Buell X1: Engine...
Page 137 Your motorcycle will run normally using this type of gas. cally compensate for heat expansion to maintain the no-lash Buell recommends you use it when possible, as an aid to ﬁt of valve train components. Hydraulic lifters and pushrods cleaner air in our environment.
Page 138 Valve trouble Compression low on ﬁrst stroke; does not build up much on follow- ing strokes; does not improve con- siderably with the addition of oil. Head gasket leak Same reaction as valve trouble. 2002 Buell X1: Engine...
Page 139 Repeat procedure on rear cylinder. CAUTION After completing the compression test(s), make sure that the throttle plate is in the closed position before starting engine. Engine will start at an extremely high RPM if throttle plate is left open. 2002 Buell X1: Engine...
Page 140: 1.6 Engine
NOTE 3.10 OIL PRESSURE INDICATOR SWITCH. At this stage, the lower rocker boxes, cylinder heads and cyl- 13. See Figure 3-2. Place a wooden cradle underneath the inders may be removed. See 3.5 CYLINDER HEAD. crankcase. 2002 Buell X1: Engine...
Page 141 20. Raise frame and walk forward over and away from the engine. 21. If necessary, remove rear swingarm assembly. See 2.19 SWINGARM. 22. If necessary, detach swingarm mount block from power- train by removing bolts (3, 4), washers and locknuts. Figure 3-4. Front Tie Bar Assembly 2002 Buell X1: Engine...
Page 142: Installing The Engine
10. Attach front upper tie bar (11). Insert bolt through tie bar front isolator, and frame. Secure with nut and washer. 24. Continue with the steps listed under ENGINE INSTALLA- Tighten to 30-33 ft-lbs (41-45 Nm). TION AFTER CYLINDER HEAD REPAIR. 3-10 2002 Buell X1: Engine...
Page 143 1.14 PRE- LOAD ADJUSTMENT. Adjust clutch lever. See 1.10 CLUTCH. Check rear brake pedal height. See BRAKES. 10. Check all electrical components for proper operation. 11. Calibrate (re-zero) TPS. See 4.36 THROTTLE POSI- TION SENSOR. 2002 Buell X1: Engine 3-11...
Page 144: Cylinder Head
Figure 3-6. Rocker Arm Cover Figure 3-7. Remove rocker arm shafts by tapping them out using a hammer and a soft metal punch. Figure 3-6. Remove rocker arms (10, 11); mark them for reassembly in their original locations. 3-12 2002 Buell X1: Engine...
Page 145 Front Isolator Mount 14. Remove both push rod covers and hydraulic lifters. See 3.15 HYDRAULIC LIFTERS. 15. Repeat the above procedure for the other cylinder head. Figure 3-9. Front Isolator Mount and Tie Bar 2002 Buell X1: Engine 3-13...
Page 146 Remove valve (10), valve stem seal (11) and lower collar (9). Repeat the above procedure for the other valve. Figure 3-11. Valve Spring Compressor (Part No. HD-34736B) Disassemble the other head using the same procedure. 3-14 2002 Buell X1: Engine...
Page 147 Figure 3-15. Measuring Rocker Arm Bushing rocker cover. Inner Diameter Check end play of rocker arm with feeler gauge. 10. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 2002 Buell X1: Engine 3-15...
Page 148 Using remaining old bushing as a pilot, line ream new bushing with ROCKER ARM BUSHING REAMER (Part No. HD-94804-57). Repeat for other end of rocker arm. 3-16 2002 Buell X1: Engine...
Page 149 Cylinder Head Holding Fixture (Part No. HD-39786) NOTE Figure 3-20. Cleaning Valve Guides The hone is not intended to remove material. Figure 3-20. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (1) (Part No. HD-34751) and hot soapy water. 2002 Buell X1: Engine 3-17...
Page 150 Part No. 622 pound as described in Step 2. To achieve a smooth even ﬁnish, place a piece of 280 grit Intake Part No. 293 Part No. 642 emery paper under the cutter head and rotate cutter. 3-18 2002 Buell X1: Engine...
Page 151 If inspection shows an unbroken lapped ﬁnish of uni- Figure 3-24. Lapping Valves form width around both valve and seat, valve is well seated. If lapped ﬁnish is not complete, further lapping (or grinding and lapping) is necessary. 2002 Buell X1: Engine 3-19...
Page 152 Clean residual loctite from threads in engine with a suitable nonﬂammable solvent and dry with com- pressed air. Apply LOCTITE THREADLOCKER 271 (red) to threads of new front isolator mount bolts. Figure 3-26. Valve Guide Seal Protector Sleeve 3-20 2002 Buell X1: Engine...
Page 153 Tighten each screw to 8-10 ft-lbs (11-14 Nm). Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-27. Mark cylinder head and head screw shoulder with a line as shown (View A). Tighten each screw a 1/4-turn (85°-90°) (View B). 2002 Buell X1: Engine 3-21...
Page 154 Place a new gasket (6) on middle rocker cover. Install upper rocker cover (4) using screws with washers (1) and new ﬁber seals (2). Tighten screws to 10-14 ft-lbs (14-19 Nm). 17. Install the other cylinder using the same procedure. 3-22 2002 Buell X1: Engine...
Page 155: Cylinder And Piston
Since the piston pin is a loose ﬁt in the piston, the pin will easily slide out. The pins have tapered ends to help seat the round retaining rings. See Figure 3-32. 1200cc piston pins are stamped with a V-groove at one end. 2002 Buell X1: Engine 3-23...
Page 156 Lay a straightedge across the surface. Try to insert a feeler gauge between the straight- edge and the gasket surface. If cylinder base gasket surface is not ﬂat within 0.008 in. (0.203 mm), replace cylinder and piston. 3-24 2002 Buell X1: Engine...
Page 157 0.020 in. OS bore with a bore size of 3.502 in. ± 0.0002 in. (88.951 mm ± 3.5200 89.4080 (0.508 mm) 0.0051 mm) for the 1200cc engine. 0.030 in. OS bore 3.5300 89.6620 (0.762 mm) 2002 Buell X1: Engine 3-25...
Page 158: Boring And Honing Cylinder
ﬁle rings to obtain proper gap. 6612 Figure 3-36. Measuring Ring End Gap Top Compression Ring – Install either side up Second Compression Ring – Install dot toward Oil Control Rings Figure 3-35. Piston Rings 3-26 2002 Buell X1: Engine...
Page 159 If the ring grooves are clean and the side play is still not cor- minimum of 90° apart rect, replace the rings, the piston or both. FRONT Piston REAR Figure 3-38. Ring End Gap Position 6614 Figure 3-39. Measuring Ring Clearance in Groove 2002 Buell X1: Engine 3-27...
Page 160 Straightening rods by bending will damage the bearing on the crank pin and the piston pin bushing. Installing bent connecting rods will damage cylinder and b0700a3x piston beyond repair. Figure 3-41. Piston Pin Bushing Tool Assembly for Bushing Removal 3-28 2002 Buell X1: Engine...
Page 161 Piston Ring Compressor Piston Support Plate 96333-51C). Figure 3-44. Compressing Piston Rings 13. Assemble cylinder head. See 3.5 CYLINDER HEAD. 14. Install cylinder head. See 3.5 CYLINDER HEAD. 15. Install assembled engine. See 3.4 INSTALLING THE ENGINE. 2002 Buell X1: Engine 3-29...
Page 162 HOME NOTES 3-30 2002 Buell X1: Engine...
Page 163: 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 164: 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 165: 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 166: Oil Pressure Indicator Switch
(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 167: 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 168: Oiling System (Color Foldout)
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 169: 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 170 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 171 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 172: Oil Filter Mount
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 173: 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 174 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 175: Gearcase Cover And Cam Gears
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 176 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 177 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 178 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 179 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 180 (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 181 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 182: Crankcase
(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 183 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 184 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 185 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 186 (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 187 (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 188 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 189 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 190 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 191 (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 192 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 193 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 194 HOME NOTES 3-62 2002 Buell X1: Engine...
Page 195 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 196 4.39 Inline Fuel Filter ..........4-106 4.40 Fuel Pump .
Page 197: Specifications
1.8-2.3 Nm page 4-108 Oxygen Sensor 42-45 ft-lbs 57-61 Nm LOCTITE ANTI-SEIZE, page 4-96 Snorkel Plate Screws LOCTITE THREADLOCKER 243 (blue), page 4- 6-8 ft-lbs 8-11 Nm Timer Plate Studs 15-30 in-lbs 2-3 Nm page 4-93 2002 Buell X1: Fuel System...
Page 198 HOME NOTES 2002 Buell X1: Fuel System...
Page 199: Dynamic Digital Fuel Injection
INTRODUCTION GENERAL The Buell Dynamic Digital Fuel Injection (DDFI) System pro- The Buell DDFI operates both as an open and closed loop vides microprocessor-based electronic engine management system which allows it to adjust for all possible operating con- for the 1203cc Buell Thunderstorm engine. The DDFI system ditions.
Page 200 12-place black connector [10] one 12-place gray connector [11] WIRE COLOR CODES USED IN THIS DOCUMENT Light Gray Violet Black Orange White Blue Pink Yellow Brown Green Figure 4-1. Buell Dynamic Digital Fuel Injection 2002 Buell X1: Fuel System...
Page 201: Diagnostic Introduction
Figure 4-3. Scanalyzer (Part No. HD-41325) of the affected components. After repairs are performed, the work must be validated. This involves clearing the trouble codes and conﬁrming proper vehicle operation as indicated by the behavior of the check engine lamp. 2002 Buell X1: Fuel System...
Page 202: Checking For Trouble Codes
Key ON Lamp remains ON: current trouble code* 4 Sec. 4 Sec. * Historic trouble code may exist Key ON ** Trouble codes 53-55, ECM failure & 56, crankshaft/camshaft timing Figure 4-5. Check Engine Lamp Operation 2002 Buell X1: Fuel System...
Page 203 +12 volts from the ignition relay. If this line should go to ground the ignition fuse will open. Always start with the trouble code having the lowest numeri- cal value. See list of fault conditions on page 4-17 (Table 4-5.) 2002 Buell X1: Fuel System...
Page 204: Scanalyzer
Figure 4-7. Scanalyzer and Cartridge the ECM. Once communications is established with the ECM, the diagnostic menu appears. See Figure 4-8. Continue with the instructions under USAGE. 2002 Buell X1: Fuel System...
Page 205 CHECK ENG= LAMP OFF TROUBLE CODE MENU 1- Display Current 2- Display Historic 3- Clear Historic MODE SYSTEM ID P/N 31652-99Y MODE BUEGC0B0 NOTE The system ID part number varies depending upon market. Figure 4-8. Scanalyzer Menus 2002 Buell X1: Fuel System...
Page 206 ﬁrm proper operation without the reoccurrence of trouble Return the handlebar engine stop switch to the RUN position codes. See 4.4 CHECKING FOR TROUBLE CODES. and restart motorcycle. NOTE For more detailed instructions, refer to the literature provided with the Scanalyzer. 4-10 2002 Buell X1: Fuel System...
Page 207: Check Engine Lamp Diagnostics
Once all codes have been sent, the data string is repeated. When you have recorded the same trouble code twice, it is an indication that the transmission has been restarted and that all trouble codes have been retrieved. 2002 Buell X1: Fuel System 4-11...
Page 208 Turn the ignition/light key switch OFF. Start the vehicle. 10. Install protective cover over data link connector. Attach connector to trunk. Let it run for at least 30 seconds. 11. Install seat. See 2.40 SEAT. Turn the engine off. 4-12 2002 Buell X1: Fuel System...
Page 209: Breakout Box
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Attach ECM to bracket with two screws. Reinstall seat. 2002 Buell X1: Fuel System 4-13...
Page 210: Wiggle Test
BOX. Set DVOM to read voltage changes. Start motorcycle engine and run at idle. Shake or wiggle harness to detect intermittents. If inter- mittents are present, radical voltage changes will register on the DVOM. 4-14 2002 Buell X1: Fuel System...
Page 211: General Information
If no problems are found after completion of the diagnos- tic check, a comparison of Scanalyzer parameters may be used to help locate intermittents and out-of-speciﬁcation sen- sors. See Table 4-1. 2002 Buell X1: Fuel System 4-15...
Page 212: Fuel Pressure Test
If RPM changes, INTAKE MANIFOLD. change seals. Improper fuel pressure 4.14 FUEL PRESSURE Ignition coil 4.16 MISFIRE. TEST. Leaky injectors Test fuel injectors. See 4.41 THROTTLE BODY AND INTAKE MANIFOLD. Valve sticking See Section 3 4-16 2002 Buell X1: Fuel System...
Page 213: Trouble Codes 23 And 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 And
4.24 TROUBLE CODE 33 Tachometer 4.25 TROUBLE CODE 35 Bank angle sensor 4.26 TROUBLE CODE 44 52, 53, 54, 55 ECM failure 4.27 TROUBLE CODES 52, 53, 54 AND 55 Cam sync failure 4.28 TROUBLE CODE 56 2002 Buell X1: Fuel System 4-17...
Page 214 Table 4-6. Wire Harness Connectors in Figure 4-17. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat [91A] Data link 4-place Deutsch behind right side of steering head 4-18 2002 Buell X1: Fuel System...
Page 215 Table 4-5. typical ranges? 4.8 WIGGLE TEST. Refer to diagnostic If Wiggle Test does not tips in related trouble recreate condition, refer code chart (even if to symptoms tables. no code is set). 7110 2002 Buell X1: Fuel System 4-19...
Page 216 [10B] Continuity present in all four circumstances? Check Scanalyzer on Inspect terminals another vehicle. for damage or repair Scanalyzer OK? opens as necessary. 7120 Scanalyzer Replace ECM. See malfunction. 4.29 ELECTRONIC CONTROL MODULE. 7125 4-20 2002 Buell X1: Fuel System...
Page 217 BK/Y wire between connectors [39] and [10]. If no continuity, check for damaged/open wires in the check engine lamp circuit. 6936 Check Engine Bulb (O and BK/Y Wires) Figure 4-20. Check Engine Lamp Bulb 2002 Buell X1: Fuel System 4-21...
Page 218 Figure 4-21. Check Engine Lamp Circuit Table 4-7. Wire Harness Connectors in Figure 4-21. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] Main harness to instruments 10-place Multilock under fuel cell 4-22 2002 Buell X1: Fuel System...
Page 219 Repair open or Repair open on O short to voltage on wire that feeds bulb BK/Y wire between or open on wire connector [39] and from bulb to con- connector [10B]. nector [39]. 7145 7140 2002 Buell X1: Fuel System 4-23...
Page 220 If the lamp goes off when the black ECM connector [10] is unplugged, the BK/Y wire is not shorted to ground. 6935 ECM Connector [11] Grey ECM Connector [10] Black Figure 4-23. Electronic Control Module 4-24 2002 Buell X1: Fuel System...
Page 221 Figure 4-24. Check Engine Lamp Circuit Table 4-8. Wire Harness Connectors in Figure 4-24. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] Main harness to instruments 10-place Multilock under fuel cell 2002 Buell X1: Fuel System 4-25...
Page 222 OK. Check for 4.29 ELECTRONIC on BK/Y wire between on BK/Y wire between trouble codes. See CONTROL MODULE. connector [39] and connector [39] and CHECKING FOR lamp in tachometer. connector [10]. 7150 TROUBLE CODES. 7165 7160 4-26 2002 Buell X1: Fuel System...
Page 223: Fuel Tank
TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat [14] CMP sensor 3-place Deutsch next to starter [18] Ignition coil 3-place Packard under fuel cell, left side 2002 Buell X1: Fuel System 4-27...
Page 224 Switch [22] Cam Position Fuel BE/O Sensor [14] Pump b0527x4x Y/BE b0617x4x Bank Angle Sensor [86] Ignition Coil [83] [134] GN/W BK/W Connector [10] Connector [11] Electronic Control Module (ECM) Figure 4-27. Ignition Circuit 4-28 2002 Buell X1: Fuel System...
Page 225 46-53 PSI (317-365 kPa). Adequate pressure? Go to Test 4.12 STOP Incorrect pressure. See 4.14 (Part 2 of 3). FUEL PRESSURE TEST. 7195 2002 Buell X1: Fuel System 4-29...
Page 226 (Part 3 of 3). Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Repair open circuit. 7240 Repair short Replace ECM. See to ground. 4.29 ELECTRONIC CONTROL MODULE. 7241 7250 4-30 2002 Buell X1: Fuel System...
Page 227 7255 Repair. Replace cam Replace cam Mechanical failure. position sensor. 7260 position sensor. Inspect for loose See Section 7. See Section 7. rotor cup and 7265 sheared pinion 7265 gear key. 7255 2002 Buell X1: Fuel System 4-31...
Page 228 Test 4.13 ﬂow chart. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. 6753 Neutral Switch (behind transmission sprocket) Connector [95] Clutch Switch Figure 4-30. Clutch Switch Figure 4-28. Neutral Switch 4-32 2002 Buell X1: Fuel System...
Page 229 Table 4-10. Wire Harness Connectors in Figure 4-31. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [22] Right handlebar switch 4-place under fuel cell, right side [95] Clutch switch 2-place clutch lever bracket 2002 Buell X1: Fuel System 4-33...
Page 230 Replace ignition relay. on right handlebar con- 7.5 STARTER nector [22] GY/O wire. INTERLOCK. Voltage present? 7276 Repair open on W/BK Replace handlebar wire between connector switch assembly. [22] and ignition relay. 7278 7277 4-34 2002 Buell X1: Fuel System...
Page 231 Open and close the air bleed petcock (4) to purge the fuel pressure gauge and hose of air. Repeat this step several times until only solid fuel (without bub- bles) ﬂows from the air bleed tube (5). Close the air bleed petcock (4). 2002 Buell X1: Fuel System 4-35...
Page 232 Test 4.14 ﬂow charts. Figure 4-35. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404), gray socket probe and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. Figure 4-35. Harness Connector Kit 4-36 2002 Buell X1: Fuel System...
Page 233 Table 4-11. Wire Harness Connectors in Figure 4-36. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] Instruments 10-place Multilock under fuel cell [86] Fuel pump 4-place Packard above rear cylinder head, left side 2002 Buell X1: Fuel System 4-37...
Page 234 ON. Is voltage greater 7457 than 1 VDC? Locate and repair poor Replace ignition relay. connection between bat- See Section 7. tery and ignition relay. 7458 7456 4-38 2002 Buell X1: Fuel System...
Page 235 3. Is continuity present? Replace fuel pump Repair fuel pump assembly. See 4.40 wiring. FUEL PUMP. 7463 7462 Replace ECM. See 4.29 Locate and repair open ELECTRONIC CONTROL on BN/Y wire. MODULE. 7466 7464 2002 Buell X1: Fuel System 4-39...
Page 236 6811 Figure 4-37. Use the adjuster attached to the throttle body to make idle speed adjustments. Normal idle speed 850-1050 RPM. Idle Adjustment Screw (Cable not Shown) Stop Plate Figure 4-37. Idle Adjustment Screw 4-40 2002 Buell X1: Fuel System...
Page 237 (GY/O and R/BK), right each end plug wire. handlebar connector [1] and coil connector. Compare resistance values to Table 4-12. Replace cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable. 2002 Buell X1: Fuel System 4-41...
Page 238 Table 4-13. Wire Harness Connectors in Figure 4-39. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [22] Right handlebar switch 4-place under fuel cell [83] Coil 3-place Packard under fuel cell, left side 4-42 2002 Buell X1: Fuel System...
Page 239 Replace known to be good. ignition coil. Perform spark test. 7535 Did spark jump gap during engine cranking? Original ignition coil Go to Test 4.16 is faulty. Replace. STOP (Part 2 of 2). 7535 2002 Buell X1: Fuel System 4-43...
Page 240 1.0 ohm? Replace cam sensor Find source with a unit known of intermittent to be good. Does and repair. problem still exist? 7540 Install original cam sensor. Replace ECM. 7542 4.29 ELECTRONIC CONTROL MODULE. 7541 4-44 2002 Buell X1: Fuel System...
Page 241 As the throttle is slowly moved, the voltage should change gradually without spikes or low voltages being observed. Scanalyzer Notes The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. 2002 Buell X1: Fuel System 4-45...
Page 242 Table 4-14. Wire Harness Connectors in Figure 4-42. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [14] Cam position sensor 3-place Deutsch near starter [88] TP sensor 3-place Packard behind air cleaner backplate 4-46 2002 Buell X1: Fuel System...
Page 243 R/W wire and short between V/Y ELECTRONIC CON- battery voltage. wire and R/W wire. 7570 TROL MODULE). Road 7585 test again to verify. 7586 7565 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-47...
Page 244 1 megaohm? Replace ECM. See 4.29 Locate and repair short ELECTRONIC CONTROL between R/W and BK/W MODULE. wires. Reconnect [14]. Clear codes and conﬁrm proper operation with no check engine 7591 7592 lamp. 4-48 2002 Buell X1: Fuel System...
Page 245 If fresh air enters exhaust system, the O2 sen- sor will read a lean condition, causing the system to go rich. Diagnostic Notes Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. 2002 Buell X1: Fuel System 4-49...
Page 246 Connector [11] Electronic Control Module (ECM) Figure 4-45. Oxygen Sensor Circuit Table 4-15. Wire Harness Connectors in Figure 4-45. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [137] Oxygen sensor 1-place above starter 4-50 2002 Buell X1: Fuel System...
Page 247 4.29 ELECTRONIC 4.29 ELECTRONIC voltage and repair. V/GY wire. CONTROL MODULE. CONTROL MODULE. 7657 7658 7659 7656 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-51...
Page 248 Air leak 7662 present? Repair. Fuel injectors may be dirty. See Fuel Injectors - 7663 Removal under 4.41 THROTTLE BODY AND INTAKE MANIFOLD. Clear codes and conﬁrm proper operation with no check engine lamp. 4-52 2002 Buell X1: Fuel System...
Page 249 CODE 13? Install original O2 sensor System and replace ECM (4.29 now OK. ELECTRONIC CONTROL 7672 MODULE). Road test again to verify. 7671 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-53...
Page 250 ET sensor at various tem- of connector [11] and system ground (Terminals 2 and 11 of perature levels in order to evaluate the possibility of a connector [10]). shifted (out-of-calibration) sensor which may result in driveability problems. 4-54 2002 Buell X1: Fuel System...
Page 251 Figure 4-46. Engine Temperature Sensor Circuit Table 4-17. Wire Harness Connectors in Figure 4-46. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [90] Engine temperature sensor 1-place bullet above rear cylinder head, left side 2002 Buell X1: Fuel System 4-55...
Page 252 Dis- lamp. regard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location. 4-56 2002 Buell X1: Fuel System...
Page 253 (but not the instruction box) if your volts and repair. normal progression through the chart brings you to this location. 7690 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-57...
Page 254: Intake Air Temperature Sensor
10 of [11] and system ground (Terminals 2 and 11 of [10]). table may be used to test the ET sensor at various tem- perature levels in order to evaluate the possibility of a shifted (out-of-calibration) sensor which may result in driveability problems. 4-58 2002 Buell X1: Fuel System...
Page 255 Figure 4-47. Intake Air Temperature Sensor Circuit Table 4-19. Wire Harness Connectors in Figure 4-47. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [89] IAT sensor 2-place Deutsch behind air cleaner backplate 2002 Buell X1: Fuel System 4-59...
Page 256 (but not the instruction box) if your short to 12 volts normal progression through the chart brings you to and repair. this location. 7745 Clear codes and conﬁrm proper operation with no check engine lamp. 4-60 2002 Buell X1: Fuel System...
Page 257 (but not the instruc- 7750 tion box) if your normal progression 7755 through the chart brings you to this location. Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-61...
Page 258: Battery Voltage
Scanalyzer Notes The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. Figure 4-49. Fuse Holder 4-62 2002 Buell X1: Fuel System...
Page 259 Switch [22] Ignition Ground Connector [10] Connector [11] Electronic Control Module (ECM) Figure 4-50. Battery Voltage Circuit Table 4-20. Wire Harness Connectors in Figure 4-50. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat 2002 Buell X1: Fuel System 4-63...
Page 260 ON. 7766 Is voltage drop greater than 0.5 volt? Replace ignition relay. STOP 7767 Go to Code 16 Test (Part 2 of 2). Clear codes and conﬁrm proper operation with no check engine lamp. 4-64 2002 Buell X1: Fuel System...
Page 261 ON. 7780 Is voltage drop greater than 0.5 volt? Replace BK wire between circuit breaker Replace circuit and battery. breaker. 7784 7779 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-65...
Page 262 The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. If a number is printed next to the icon, then refer to the Scanalyzer notes at the bot- tom of the ﬂow chart. 4-66 2002 Buell X1: Fuel System...
Page 263 Figure 4-53. Fuel Injector Circuit Table 4-21. Wire Harness Connectors in Figure 4-53. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [84] Front injector 2-place under fuel cell [85] Rear injector 2-place under fuel cell 2002 Buell X1: Fuel System 4-67...
Page 264 Test Mode) can be used to turn fuel pump on for or rear injector once each second for a total of ﬁve periods up to 30 seconds. Power to the pump also seconds. includes power to the fuel injectors and ignition coil. 4-68 2002 Buell X1: Fuel System...
Page 265 Test Mode) can be used to turn fuel pump on for or rear injector once each second for a total of ﬁve periods up to 30 seconds. Power to the pump also seconds. includes power to the fuel injectors and ignition coil. 2002 Buell X1: Fuel System 4-69...
Page 266: Trouble Codes 24 And
Scanalyzer can be used. If a number is printed next to the icon, then refer to the Scanalyzer notes at the bot- tom of the ﬂow chart. Battery Figure 4-55. Testing Ignition Coil Connectors 4-70 2002 Buell X1: Fuel System...
Page 267 Figure 4-56. Ignition Coil Circuit Table 4-22. Wire Harness Connectors in Figure 4-56. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [83] Ignition coil connector 3-place Packard under fuel cell, left side 2002 Buell X1: Fuel System 4-71...
Page 268 Test Mode) can be used to turn fuel pump on for or rear injector once each second for a total of ﬁve periods up to 30 seconds. Power to the pump also seconds. includes power to the fuel injectors and ignition coil. 4-72 2002 Buell X1: Fuel System...
Page 269 Scanalyzer Notes The Scanalyzer icon appears at those points in the ﬂow chart where the Scanalyzer can be used. Ignition Fuse Spare Fuse slot (may be 15 or 20 Amp) Figure 4-58. Ignition Fuse 2002 Buell X1: Fuel System 4-73...
Page 270 Table 4-23. Wire Harness Connectors in Figure 4-59. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] Instruments 10-place Multilock under fuel cell [86] Fuel pump 4-place Packard above rear cylinder head, left side 4-74 2002 Buell X1: Fuel System...
Page 271 (4.40 FUEL PUMP) and replace ECM 7893 (4.29 ELECTRONIC CONTROL MODULE). 7892 Replace fuel pump. See Repair 4.40 FUEL PUMP. open. 7897 7898 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-75...
Page 272 Inadequate safety precautions could result in death or serious injury. Purge fuel line and remove fuel tank to access instru- ment connector [39]. See 4.37 FUEL TANK. Replace tachometer. See 7.18 TACHOMETER. Figure 4-61. Speedometer/Tachometer Connector [39] 4-76 2002 Buell X1: Fuel System...
Page 273 Electronic Control Module (ECM) Figure 4-62. Tachometer Circuit Table 4-24. Wire Harness Connectors in Figure 4-62. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] Main harness to instruments 10-place Multilock under fuel cell 2002 Buell X1: Fuel System 4-77...
Page 274 Reconnect [39]. Locate Replace ECM. See 4.29 intermittents using ELECTRONIC CON- WIGGLE TEST. Intermit- TROL MODULE. tents found? 7882 Repair. Replace tachometer. 7881 7883 Clear codes and conﬁrm proper operation with no check engine lamp. 4-78 2002 Buell X1: Fuel System...
Page 275: Bank Angle Sensor
41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.7 BREAKOUT BOX. When vehicle lean angle exceeds 55 , ECM shuts off ignition and fuel systems. Figure 4-64. Bank Angle Sensor Operation 2002 Buell X1: Fuel System 4-79...
Page 276 Figure 4-65. Bank Angle Sensor Circuit Table 4-25. Wire Harness Connectors in Figure 4-65. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [134] Bank angle sensor 3-place Packard under tail section, left side 4-80 2002 Buell X1: Fuel System...
Page 277 Install properly. See 4.34 BANK 0.25 in. (6.4 mm) of sides, face or ANGLE SENSOR. top of bank angle sensor? 7976 Replace bank angle sensor. See 4.34 Return to original BANK ANGLE SENSOR. configuration. 2002 Buell X1: Fuel System 4-81...
Page 278 Is continuity present? 7975 Repair short to ground Replace ECM. See on Lt GN/GY wire. 4.29 ELECTRONIC CONTROL MODULE. 7973 7974 Clear codes and conﬁrm proper operation with no check engine lamp. 4-82 2002 Buell X1: Fuel System...
Page 279 Code 54 - EE PROM failure. Code 55 - Microprocessor failure. NOTE Dealership technicians ﬁling warranty claims should use job/ time code 7913 for all Code 52, 53, 54 and 55 ECM replace- ments. 2002 Buell X1: Fuel System 4-83...
Page 280 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), black pin probes and patch cord. Timer Plate Stud (2) 4.30 CAM POSITION SENSOR AND ROTOR. Sensor Wiring Cam Position Sensor b0313a7x Figure 4-66. Cam Position Sensor 4-84 2002 Buell X1: Fuel System...
Page 281 Table 4-26. Wire Harness Connectors in Figure 4-67. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [14] Cam position sensor 3-place Deutsch near starter [88] TP sensor 3-place Packard behind air cleaner backplate 2002 Buell X1: Fuel System 4-85...
Page 282 4.29 ELEC- connectors [11] and connectors [11] and to ground. to voltage. TRONIC CON- [14]. [14]. TROL MODULE. 7970 7955 7965 7945 7945 Clear codes and conﬁrm proper operation with no check engine lamp. 4-86 2002 Buell X1: Fuel System...
Page 283 7940 lem still exist? for damage. 7940 7951 Install original cam System position sensor. Replace ECM. See 4.29 ELECTRONIC 7952 CONTROL MODULE. 7960 Clear codes and conﬁrm proper operation with no check engine lamp. 2002 Buell X1: Fuel System 4-87...
Page 284: Electronic Control Module
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.40 SEAT. 4-88 2002 Buell X1: Fuel System...
Page 285 Sensor ground 1 Injector rear output Sensor ground 2 No function Engine temperature input Bank angle sensor input Intake air temperature input System ground B (coil) Serial data receive Tachometer out Serial data transmit 2002 Buell X1: Fuel System 4-89...
Page 286: Cam Position Sensor And Rotor
Remove timer plate studs. Carefully remove cam position sensor. Remove bolt (6) and trigger rotor (8). 10. Carefully remove camshaft oil seal (9) if damaged or if there is any evidence of oil leakage past the seal. 4-90 2002 Buell X1: Fuel System...
Page 287 13. Front Spark Plug Cable 14. Rear Spark Plug Cable 15. Cable Strap 16. Terminal Pin 17. Cam Position Sensor Connector [14] 18. Secondary Lock 19. Electronic Control Module (ECM) 20. Screw (2) b0764x7x Figure 4-72. Ignition Components 2002 Buell X1: Fuel System 4-91...
Page 288 HOME Figure 4-73. Ignition and Starting System Circuit 4-92 2002 Buell X1: Fuel System...
Page 289 Use of regular rivets can damage ignition system components and may allow water to enter the timing compartment. 10. Secure timer cover (2) to inner cover using new rivets. 2002 Buell X1: Fuel System 4-93...
Page 290: Ignition Coil
An inﬁnite ohms (∞ or no continuity) resistance value indicates an open circuit (a break in the coil winding). Replace coil. 4-94 2002 Buell X1: Fuel System...
Page 291 Figure 4-78. Ignition Coil 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. Connect battery cables, positive cable ﬁrst. 2002 Buell X1: Fuel System 4-95...
Page 292 Make sure anti-seize is marked as safe for use with O2 sensors. Figure 4-79. Thread sensor into exhaust header. Tighten sensor to 42-45 ft-lbs (57-61 Nm). Connect 1-place connector [137] to wiring harness. 4-96 2002 Buell X1: Fuel System...
Page 293 Orient the rubber boot so the ﬂat on the boot is towards the left side of the motorcycle. Route ET sensor wire lead through opening at rear of cylinder head, under rocker box and cover and connect ET sensor 1-place connector [90] to wiring harness. 2002 Buell X1: Fuel System 4-97...
Page 294 Install bank angle sensor to mounting tab with screw and new locknut. Tighten screw to 25-27 in-lbs (2.8-3.1 Nm). Figure 4-82. Plug connector [134] into bank angle sensor. 4-98 2002 Buell X1: Fuel System...
Page 295 Install long bolt and washer ﬁrst. Align air cleaner cover and secure with two screws and washers. Tighten screws to 27-29 in lbs (3.1- Figure 4-84. Intake Air Temperature Sensor Installed 3.3 Nm). 2002 Buell X1: Fuel System 4-99...
Page 296 TP degree reading reaches 5.8. Start engine and bring the engine temperature to a minimum of 265° F (129.4° C). Set the warm idle speed at 1000-1100 rpm with the idle adjuster cable. 4-100 2002 Buell X1: Fuel System...
Page 297: Fuel Tank
Figure 4-88. Fuel Tank Mount Remove fuel line from fuel supply ﬁtting. Figure 4-89. Disconnect hose from vapor vent valve. Remove fuel tank from frame. b0546aox Vent Valve Assembly Figure 4-89. Vapor Vent Valve 2002 Buell X1: Fuel System 4-101...
Page 298 Shake tank to agitate agent. Figure 4-91. Tightening Sequence (Typical) Thoroughly ﬂush fuel tank after cleaning. Allow tank to air dry. Carefully inspect fuel hose and vent hose for damage, wear or general deterioration. Replace as necessary. 4-102 2002 Buell X1: Fuel System...
Page 299 Use a good quality unleaded gasoline (91 pump octane or higher). Octane rating is usually found on the pump. Fill fuel tank. Turn ignition key ON and listen for fuel pump activation. Carefully inspect for leaks. 2002 Buell X1: Fuel System 4-103...
Page 300: Fuel Tank Vent Valve
Step 6. Figure 4-93. Align ﬁtting so right front point of hex is oriented to 12:00 position when ﬁtting is tightened ﬁnger tight. Make sure O-ring remains in groove of ﬁtting while tightening. 4-104 2002 Buell X1: Fuel System...
Page 301 Fill fuel tank with proper fuel (91 Octane) and install gas cap. 10. Connect negative battery cable. Tighten battery terminal Figure 4-93. Fuel Tank Vent Alignment hardware to 60-96 in-lbs (7-11 Nm). 11. Pressurize fuel system. 12. Check for leaks. 2002 Buell X1: Fuel System 4-105...
Page 302: Inline Fuel Filter
ﬂow. Make sure to push fuel hoses all the way on to ﬁttings and position hose clamp on ﬁtting side of barb. Install fuel tank. See 4.37 FUEL TANK. Pressurize fuel system and check for leaks. 4-106 2002 Buell X1: Fuel System...
Page 303: Fuel Pump
Operating Voltage 14 volts Place a new retaining clamp (5) over pump body. Posi- Fuel Delivery 70 LPH @ 49 PSI tion clamp inside groove (8) on pump holder housing. Current Draw 3 amps 2002 Buell X1: Fuel System 4-107...
Page 304 Figure 4-99. Rubber Seals and Washers Apply two drops of LOCTITE THREADLOCKER 243 (blue) to middle threads of the fuel and electrical outlet studs. Use care to avoid getting threadlocker on the fuel tank. Install nuts on studs. 4-108 2002 Buell X1: Fuel System...
Page 305: Throttle Body And Intake Manifold
Screw (metric) 10. Injector Seals (4) 11. Injector (2) 12. Intake Manifold 13. Screw (4) 14. Intake Flange (2, Front and Rear) 15. Intake Seal (2) b0784x4x Figure 4-100. Throttle Body and Intake Manifold 2002 Buell X1: Fuel System 4-109...
Page 306 Separate fuel rail from injectors (1, 2) by gently rock- rioration. Replace O-rings if they have been damaged or ing the fuel rail and pulling it away from the injectors. have taken a deﬁnite set. 4-110 2002 Buell X1: Fuel System...
Page 307 Install screw and throttle cable brackets to throttle cables. Verify operation by turning throttle grip and observ- Cable End ing the cable action and throttle valve movement. Guide Slot Figure 4-105. Idle Control Cable Installation 2002 Buell X1: Fuel System 4-111...
Page 308 Calibrate throttle position sensor if removed or replaced. 4.36 THROTTLE POSITION SENSOR. 10. Install air cleaner backplate and cover. See 4.42 AIR CLEANER. 11. Check throttle cable adjustment. 6-10 ft-lbs (8-14 Nm) Figure 4-107. Intake Flange Screws, Primary Cover Side 4-112 2002 Buell X1: Fuel System...
Page 309: Air Cleaner
(25) in clamps (26). Tighten screws to 3-5 ft-lbs (4-7 Nm) after installing all three fasteners. Install bolt (22) and washer (2) to secure backing plate to vehicle frame. Install IAT sensor (11) and grommet (12) into snorkel (7). 2002 Buell X1: Fuel System 4-113...
Page 310 26. Clamp (3) Snorkel, Internal 17. Screw (3) 27. Screw Snorkel Plate 18. Washer (3) 28. Gasket Screw 19. Breather Hose 29. IAT Connector [89] and Wiring 10. Gasket (2) 20. Grommet Figure 4-108. Air Cleaner 4-114 2002 Buell X1: Fuel System...
Page 311: Evaporative Emissions Control-California Models
HOME EVAPORATIVE EMISSIONS CONTROL-CA MODELS 4.43 GENERAL Buell motorcycles sold in the state of California are equipped Post with an evaporative (EVAP) emissions control system. The Check Ball EVAP system prevents fuel hydrocarbon vapors from escap- ing into the atmosphere and is designed to meet the Califor- nia Air Resource Board (CARB) regulations in effect at the time of manufacture.
Page 312 Screw, Washer and Locknut (2) in death or serious injury. Install vent valve. See 4.38 FUEL TANK VENT VALVE. Figure 4-110. Attach fuel tank vent hose (1) to can- ister if disconnected. Figure 4-112. Carbon Canister Mounting 4-116 2002 Buell X1: Fuel System...
Page 313 (2) to the carbon canister. Canister vent hose attaches to the top ﬁtting. Make sure to push fuel tank vent hose all the way on to carbon canister ﬁtting and position hose clamp on ﬁtting side of barb. 2002 Buell X1: Fuel System 4-117...
Page 314 HOME NOTES 4-118 2002 Buell X1: Fuel System...
Page 315 Table Of Contents ELECTRIC STARTER SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 316 TORQUE VALUES ITEM TORQUE NOTES Battery Terminal Hardware 60-96 in-lbs 7-11 Nm page 5-18 Starter Battery Positive Cable Nut 60-85 in-lbs 7-10 Nm metric, page 5-18 Starter Mounting Bolts 13-20 ft-lbs 18-27 Nm page 5-18 2002 Buell X1: Electric Starter...
Page 317: Electric Starter System
The solenoid plunger (7) is returned to its original 7.5 STARTER INTERLOCK for operation and trouble- position by the return spring, which causes the pinion gear shooting information. (1) to disengage from the clutch ring gear (13). 2002 Buell X1: Electric Starter...
Page 318 Idler Gear Field Winding Armature Brush Ball Bearing Solenoid Plunger Main Solenoid Contacts Battery 10. Pull-in Winding Starting circuit-see 11. Hold-in Winding wiring diagram 12. Overrunning Clutch 13. Clutch Ring Gear Figure 5-1. Starter Operation 2002 Buell X1: Electric Starter...
Page 319 Coil layer shorted. Replace solenoid. Contact plate melted and stuck. Replace solenoid. Starting switch or Unopened contacts. Replace starting switch or starter starter relay. relay. Poor returning. Replace starting switch or starter relay. 2002 Buell X1: Electric Starter...
Page 320: Starting System Diagnosis
Circuit or Button to Relay. Battery Voltage Present? Correct Relay 5832 5831 Ground. 5828 Replace Right Repair Wiring to Motor Terminal Battery Terminal Handlebar Starter Button. Switchgear. 5831 5816 Figure 5-2. Starting System Diagnosis, Part 1 2002 Buell X1: Electric Starter...
Page 321 5.6 STARTER SYSTEM Primary Drive. for Opens, Shorts or Grounds. TESTING. Replace or Repair FREE RUNNING CURRENT DRAW TEST. Starter Motor. DIAGNOSTICS in 7.5 STARTER INTERLOCK. 5817 Figure 5-3. Starting System Diagnosis, Part 2 2002 Buell X1: Electric Starter...
Page 322: Starter Activation Circuits
GROUND CIRCUIT 0.1A 0.1A 0.1A 0.1A 150A 150A 150A 150A Start Switch Main Circuit Breaker Relay Ignition Switch Solenoid Ignition Circuit Starter Breaker Battery Figure 5-4. Typical Circuity. Refer to wiring diagrams for more information. 2002 Buell X1: Electric Starter...
Page 323: Diagnostics/Troubleshooting
ITEM C Figure 5-4. An open circuit should read drop or potential difference in the ground circuit. 12 volts, displaying all the voltage dropped, and the entire difference in potential displayed on the meter. 2002 Buell X1: Electric Starter...
Page 324 2002 Buell X1: Electric Starter...
Page 325 HOME NOTES 5-10 2002 Buell X1: Electric Starter...
Page 326: Starter System Testing
Typical starter current draw will range between 140- 180 amperes. If starter current draw exceeds 180 amperes, then the problem may be in the starter or starter drive. Remove starter for further tests. See STARTER. 2002 Buell X1: Electric Starter 5-11...
Page 327: Starter
Check ammeter reading. problem with engine or primary drive. Ammeter should show 90 amps maximum. If reading is higher, disassemble starter for inspec- tion. See STARTER. 5-12 2002 Buell X1: Electric Starter...
Page 328 Figure 5-14. Return Test Observe starter pinion. If starter pinion returns to its original position, sole- noid is working properly. If starter pinion does not return to its original posi- tion, replace the solenoid. 2002 Buell X1: Electric Starter 5-13...
Page 329 After undercutting, lightly sand the commutator with crocus cloth to remove any burrs. Field Frame Brush Holder Brush Spring (4) Armature Solenoid Housing Figure 5-17. Starter Components 5-14 2002 Buell X1: Electric Starter...
Page 330 Replace Replace grounded armatures. shorted armatures. 1782a 6011 Figure 5-19. Shorted Armature Test Using Growler Figure 5-20. Grounded Armature Test 2002 Buell X1: Electric Starter 5-15...
Page 331 Touch the other probe to each of the positive (insu- lated) brush holders (2). There should be no continuity (inﬁnite ohms). If there is continuity at either brush holder, replace the brush holder assembly. 5-16 2002 Buell X1: Electric Starter...
Page 332 10. Drive Housing 11. Solenoid Housing 12. Drive Assembly/ Overrunning Clutch 13. Idler Gear 14. Idler Gear Roller (5) 15. Idler Gear Bearing Cage 16. O-Ring 17. Return Spring 18. Ball Figure 5-26. Starter Assembly 2002 Buell X1: Electric Starter 5-17...
Page 333 Connect solenoid wire (4). Attach circuit breaker wire ring terminal (3). Attach positive battery cable ring terminal (2). Install nut with washer (1) (metric). Tighten to 60-85 in-lbs (7-10 Nm). Replace protective boot if present. 5-18 2002 Buell X1: Electric Starter...
Page 334: Starter Solenoid
Replace wire connection hardware as Figure 5-27. Starter Solenoid necessary. Install plunger (5) in solenoid housing (6). Install new gasket (4) onto cover (3). Position cover with gasket onto solenoid housing. Install clip (2) and screws (1). 2002 Buell X1: Electric Starter 5-19...
Page 335 HOME NOTES 5-20 2002 Buell X1: Electric Starter...
Page 336 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Chain .
Page 337 0.152 0.661 16.789 Clutch Pack minimum minimum NOTE Service wear limits are given as a guideline for measuring components that are not new. For measurement speciﬁca- tions not given under SERVICE WEAR LIMITS, see NEW COMPONENTS. 2002 Buell X1: Drive/Transmission...
Page 338 68 Nm then an Transmission Sprocket Nut an additional additional 30-40 hand threads, special torque & turn 30-40 degrees degrees method, page 6-35 Transmission Sprocket Screws 90-110 in-lbs 10-12 Nm replace after 3 removals, page 6-36 2002 Buell X1: Drive/Transmission...
Page 339 Lockplate Wellnut Coupling Ramp Assembly Quad Ring Drain Plug and O-ring 10. Locknut 11. Chain Adjuster Screw 12. Primary Cover 13. Primary Chain Inspection Cover 14. Clutch Adjusting Screw 15. Oil Seal Figure 6-1. Primary Cover 2002 Buell X1: Drive/Transmission...
Page 340 Thread adjuster screw into tapped boss at bottom of primary cover. At outside of cover, install locknut (2) onto adjuster screw with nylon sealing surface toward cover. Tighten to 20-25 ft-lbs (27- 34 Nm). Install primary cover. 2002 Buell X1: Drive/Transmission...
Page 341 16. Tighten pinch screw to 59-66 in-lbs (7-8 Nm). (37-39 Nm) Blue Loctite 17. Tighten mounting bolt to 27-29 ft-lbs (37-39 Nm). 18. Install mufﬂer. See 2.28 EXHAUST SYSTEM. 19. Connect negative battery cable to battery. Figure 6-5. Shifter Lever 2002 Buell X1: Drive/Transmission...
Page 342: Drive Belt
REMOVAL Belt removal requires special lifts to support the motorcycle. If Axle Nut you do not have the proper equipment, have your Buell dealer Lockwasher perform the repair. Washer Axle Carrier Lift and secure the motorcycle.
Page 343 Tighten footrest mount bolts (4) to 10-15 ft-lbs (14- 20 Nm). Install chin fairing. See 2.34 CHIN FAIRING. Install stone guard and belt guard. See 2.33 BELT GUARDS. Connect the negative battery cable to the battery. 2002 Buell X1: Drive/Transmission...
Page 344: Clutch Release Mechanism
Wellnut Outer Ramp Ball (3) O-Ring Cable End Fitting 10. Clutch Cable End 11. Primary Cover 12. Clutch Adjusting Screw 13. Retaining Ring 14. Quad Ring 15. Inner Ramp 16. Coupling Figure 6-10. Clutch Release Mechanism 2002 Buell X1: Drive/Transmission...
Page 345 6240 Adjust clutch release mechanism. See 1.10 CLUTCH. Connect negative battery cable to battery terminal. Outer Ramp Wellnut Adjusting Screw Cable End Coupling Slot of Primary Cover Figure 6-12. Nut and Outer Ramp 2002 Buell X1: Drive/Transmission...
Page 346: Primary Drive/Clutch
Worn clutch release ramps or balls. Replace release ramps and/or balls. Warped clutch steel plates. Replace clutch steel plates. Blade worn or damaged clutch gear splines. Replace clutch gear or hub as required. Overﬁlled primary. Drain lubricant to correct level. 6-10 2002 Buell X1: Drive/Transmission...
Page 347 Remove pressure plate assembly. Figure 6-15. Pressure Plate Assembly Figure 6-16. Remove the clutch pack from the hub/ shell assembly. The pack consists of eight ﬁber plates (18), six steel plates (19) and a spring plate (20). 2002 Buell X1: Drive/Transmission 6-11...
Page 348 13. Release Plate 19. Steel Plate (6) 25. Bearing 14. Retaining Ring 20. Spring Plate 26. Clutch Shell 15. Bearing 21. Mainshaft Nut 27. Retaining Ring 22. Washer 16. Adjusting Screw Figure 6-16. Clutch Assembly 6-12 2002 Buell X1: Drive/Transmission...
Page 349 Remove and discard small retaining ring (3) and then separate the adjusting screw (4) from the bear- Remove clutch pack components. See Steps 3-4 of ing and release plate (2). Remove bearing from CLUTCH PACK under 6.5 PRIMARY DRIVE/CLUTCH. release plate. 2002 Buell X1: Drive/Transmission 6-13...
Page 350 If clutch shell was removed from motorcycle, check the bearing for smoothness. Rotate the clutch shell while holding the clutch hub. If bearing is rough or binds, it must be replaced. 6-14 2002 Buell X1: Drive/Transmission...
Page 351 Place bearing inside release plate. Insert adjusting screw (4) through bearing and release plate (2). Secure with new retaining ring (3). Figure 6-21. Position diaphragm spring (1) with its concave side facing toward pressure plate onto pressure plate assembly. 2002 Buell X1: Drive/Transmission 6-15...
Page 352 Washer Figure 6-17. Secure the adjusting screw Clutch Hub assembly with retaining ring. Figure 6-24. Mainshaft Nut and Washer Install primary cover. See 6.2 PRIMARY CHAIN. Connect negative battery cable to negative battery termi- nal. 6-16 2002 Buell X1: Drive/Transmission...
Page 353 Drain transmission and reﬁll to correct level with fresh, clean lubricant at least once each year or every 5000 miles (8000 DOWNSHIFT km), whichever comes ﬁrst. For best results, drain lubricant while hot. 1.10 CLUTCH for more information. Figure 6-25. Transmission Shift Pattern 2002 Buell X1: Drive/Transmission 6-17...
Page 354 XLH transpower flow Neutral 1st Gear Mainshaft Mainshaft Countershaft Countershaft 3rd Gear 2nd Gear Mainshaft Mainshaft Countershaft Countershaft 5th Gear 4th Gear Mainshaft Mainshaft Countershaft Countershaft – Sliding Member – Power Flow Figure 6-26. Transmission Power Flow 6-18 2002 Buell X1: Drive/Transmission...
Page 355: Transmission Case
Transmission Sprocket Nut (left-hand threads) Lockplate Remove primary cover. See 6.2 PRIMARY CHAIN. Socket Head Screw (2) 10. Remove clutch assembly, primary chain and engine Figure 6-28. Transmission Sprocket sprocket. See PRIMARY CHAIN/DRIVE under 6.5 PRI- MARY DRIVE/CLUTCH. 2002 Buell X1: Drive/Transmission 6-19...
Page 356 Neutral Indicator Switch Figure 6-31. The neutral indicator switch is threaded into the transmission portion of the right crankcase half. See 7.22 Figure 6-31. Neutral Indicator Switch NEUTRAL INDICATOR SWITCH for testing, removal and installation procedures. 6-20 2002 Buell X1: Drive/Transmission...
Page 357: Shifter Forks And Drum
18. Detent Screw Shifter Fork Pin (3) 12. Locknut (2) 19. Mainshaft Bearing Neutral indicator Pin 13. Detent Plate (Typical) 20. Countershaft Bearing Shifter Fork Drum 14. Washer (2) 21. Washer (2) Figure 6-32. Shifter Mechanism 2002 Buell X1: Drive/Transmission 6-21...
Page 358 These parts are installed during 10. Nut Detent Screw transmission installation after the ﬁnal shifter pawl adjustment Spring 11. Pin is made. See 6.13 TRANSMISSION INSTALLATION AND SHIFTER PAWL ADJUSTMENT. Figure 6-34. Detent Plate Mounting 6-22 2002 Buell X1: Drive/Transmission...
Page 359 HOME Detent Plate 3557 (Typical) Detent Roller Countershaft Bearing Figure 6-35. Detent Roller Arm 2002 Buell X1: Drive/Transmission 6-23...
Page 360: Mainshaft And Countershaft
Using RETAINING RING PLIERS (Part No. J-5586) remove and discard retaining ring (5) next to countershaft 5th gear (12). Slide countershaft 5th (12), mainshaft 2nd (22) and countershaft 2nd (11) off end of xlh0626 shafts. Figure 6-38. 6-24 2002 Buell X1: Drive/Transmission...
Page 361 18. Ring, Retaining 32. TORX Screw 19. Bearing, Ball 33. Ring, Retaining 20. Bearing, Needle 34. Nut, Mainshaft 21. Gear, Mainshaft 5th 35. Washer, Spring 22. Gear, Mainshaft 2nd 36. Bushing Figure 6-39. Transmission Assembly 2002 Buell X1: Drive/Transmission 6-25...
Page 362 (8). Remove retaining ring (5) and thrust washer (6). Slide countershaft 1st gear off end of shaft. Remove split bearing (7). 10. Remove thrust washer (6). Expand remaining retaining ring (5) and slide off shaft. This completes disassembly Figure 6-42. of countershaft. 6-26 2002 Buell X1: Drive/Transmission...
Page 363 (28) resting on the section of pipe. Insert the splined end of the shaft through the bearing and hold in a vertical position. Press the shaft into the bearing until the bearing bottoms against the shaft shoulder. Press Figure 6-44. 2002 Buell X1: Drive/Transmission 6-27...
Page 364 Hold assembly straight, making sure gear teeth on coun- tershaft are engaged with gear teeth on mainshaft, and press bearing onto shaft until beveled spacer bottoms against bearing. Blocks NOTE When correctly installed, countershaft 4th gear should have Figure 6-47. zero end play. 6-28 2002 Buell X1: Drive/Transmission...
Page 365 (32). Insert TORX screw (32) through retention collar and thread into end of shaft. Place transmission in 6180 gear and tighten TORX screw to 13-17 ft-lbs (18-23 Nm). 20. Install shifter forks and drum. See 6.8 SHIFTER FORKS DRUM. Figure 6-50. 2002 Buell X1: Drive/Transmission 6-29...
Page 366: Main Drive Gear
For Outer Bearing For Seal 0.06-0.03 in. (1.52-0.76 mm) Support Bracket Bolt 5th Gear Driver Main Drive Gear Thrust Washer Needle Bearing Seal Figure 6-51. Main Drive Gear Assembly Figure 6-53. Removing Main Drive Gear 6-30 2002 Buell X1: Drive/Transmission...
Page 367 (4) bottoms against inner race Bolt of bearing. Installer Cup Figure 6-51. Tap in new seal (3) at threaded end of 5th Gear 5th gear. Washer Figure 6-55. Main Drive Gear Installation 2002 Buell X1: Drive/Transmission 6-31...
Page 368: Access Door Bearings
Assemble bushing flush to 0.020 in. (0.508 mm) recess from this surface Shift Drum Bushing Retaining Ring Retaining Ring Bearing, Mainshaft Bearing, Countershaft Figure 6-56. Ball Bearing Assembly Figure 6-57. Shift Drum Bushing Assembly 6-32 2002 Buell X1: Drive/Transmission...
Page 369: Right Transmission Case Bearings
The bearing is properly positioned when driven inward ﬂush or 0.030 in. (0.762 mm) below the outside surface. Lubricate bearing with SPORT-TRANS FLUID. 2002 Buell X1: Drive/Transmission 6-33...
Page 370: Transmission Installation And Shifter Pawl Adjustment
Place new quad ring (17) over threaded end of ﬁfth gear (21), and position next to the gear taper. Install spacer (16) over threaded end of ﬁfth gear with chamfered end toward quad ring. Slide spacer up against bearing (19). 6-34 2002 Buell X1: Drive/Transmission...
Page 371 12. If you cannot align lockplate and sprocket screw holes, nut may be additionally tightened until screw holes align. 2002 Buell X1: Drive/Transmission 6-35...
Page 372 15. Adjust drive belt tension. See 1.11 DRIVE BELT 30° DEFLECTION. 16. Fill transmission to proper level with fresh lubricant. See 1.10 CLUTCH. Line scribed on nut and sprocket Figure 6-64. Aligning Transmission Sprocket 6-36 2002 Buell X1: Drive/Transmission...
Page 373 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 374: Specifications
68024-94 on Instrument Oil Pressure Indicator 0.15 68024-94 Support Neutral Indicator 0.15 68024-94 Speedometer Illumination 0.14 67421-99Y Tachometer Illumination 0.14 68073-99Y Instruments Low Fuel Lamp (in Tachometer) 0.14 68073-99Y Check Engine Lamp (in 0.14 68073-99Y Tachometer) 2002 Buell X1: Electrical...
Page 375 7-22 Turn Signal Nut (Rear) 96-120 in-lbs 11-14 Nm page 7-35 Turn Signal Screws (Front) 25-28 in-lbs 2.8-3.2 Nm page 7-34 Voltage Regulator Mounting Screws 9-11 ft-lbs 12-15 Nm page 7-23 2002 Buell X1: Electrical...
Page 376: Ignition System
The ECM will provide a richer fuel mixture on start up and a higher degree of spark advance. As the vehicle warms up to operating temperature the fuel mix- ture will lean and the spark advance will decrease. 2002 Buell X1: Electrical...
Page 377 13. Front Spark Plug Cable 14. Rear Spark Plug Cable 15. Cable Strap 16. Terminal Pin 17. CMP Connector [14] 18. Secondary Lock 19. Ignition Module 20. Washer (2) 21. Screw (2) b0764x7x Figure 7-1. Ignition System Components 2002 Buell X1: Electrical...
Page 378: Ignition/Headlamp Key Switch
Remove four screws and washers to detach windscreen from mounting brackets. Disconnect ignition key switch connector [33] from main wiring harness. Figure 7-2. Remove ignition switch face nut (2). Remove ignition switch (1) from behind dash panel. 2002 Buell X1: Electrical...
Page 379 Check ignition key switch for proper operation. If opera- tion fails, reread procedure and verify that all steps were performed. Install four screws and washers to attach windscreen to mounting brackets. 2002 Buell X1: Electrical...
Page 380: Spark Plug Cables
Connect spark plug cables to ignition coil and spark plugs. Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. NOTE 1.18 SPARK PLUGS for spark plug information. 2002 Buell X1: Electrical...
Page 381: Starter Interlock
Listen for relay “click”. If click is not heard, perform stand retracted or clutch disengaged. ignition system tests. Motorcycle will not start after starter No spark at spark plug. Check for 12 VDC at coil W/BK wire. relay tests. Follow ignition system troubleshooting. 2002 Buell X1: Electrical...
Page 382 Continuity Infinite ohms Figure 7-5. Ohmmeter Diode Test TN/GN To Clutch Switch [95] b0644x4x TN/GN Diode 1 Polarity TN/W Ignition Relay TN/GN TN/W Diode 2 Polarity Relay Block Figure 7-6. Diode Polarity Figure 7-7. Diode Wiring 2002 Buell X1: Electrical...
Page 383 Diode OK? Check for ground at neutral switch terminal. Ground present? Repair open on TN wire Replace Diode installed Replace between neutral switch neutral backwards. Reverse diode. and Diode 2. switch. polarity. 5062 5061 5063 5064 7-10 2002 Buell X1: Electrical...
Page 384 [95]. GN wire between Reverse polarity. Ground present? connector [95] and 5072 Diode 2. 5071 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 2002 Buell X1: Electrical 7-11...
Page 385 HOME Figure 7-8. Starter/Ignition Interlock System 7-12 2002 Buell X1: Electrical...
Page 386 Depress clutch lever and hold. Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar. Clutch Engaged (switch open) Install new switch. Clutch Disengaged (switch closed) Connector [95] Figure 7-10. Clutch Switch 2002 Buell X1: Electrical 7-13...
Page 387 Mounting Tabs Attached to the frame above the battery, the main circuit Figure 7-12. Ignition Relay and Diodes breaker links the ignition key switch and the battery. See 7.23 FUSES AND CIRCUIT BREAKERS for more information. 7-14 2002 Buell X1: Electrical...
Page 388: Charging System
Figure 7-14. Stator Connector [46] as battery ground cable, and the other on the regulator base. Figure 7-14. Connector plug to stator must be clean and tight. 2002 Buell X1: Electrical 7-15...
Page 389 Accessories on when vehicle is ridden Damaged or Perform CURRENT OUTPUT Fail very slowly for long periods. slipping rotor. TEST. Battery self-discharge and/or acces- sory draw because vehicle was not operated for a long period. Figure 7-15. Charging System Troubleshooting 7-16 2002 Buell X1: Electrical...
Page 390 HOME b0749chr b0749chr Main chassis Main Chassis ground Ground Master circuit Main Circuit breaker Breaker Voltage Regulator Starter Starter [46] Battery Stator Figure 7-16. Charging System Circuit 2002 Buell X1: Electrical 7-17...
Page 391 CURRENT AND VOLTAGE OUTPUT TEST. The current output should exceed current draw by 3.5 amps minimum. If output does not meet speciﬁcations, there may be too many accessories for the charging system to handle. Reconnect regulator after testing. 7-18 2002 Buell X1: Electrical...
Page 392 Test for resistance with ohmmeter set on the RX1 scale. Resistance across the stator sockets should be 0.2- 0.4 ohms. b0733a7x If the resistance is lower, the stator is damaged and Figure 7-21. Check for Stator Resistance must be replaced. 2002 Buell X1: Electrical 7-19...
Page 393 If output is good, charging problem might be faulty regulator/rectiﬁer. Replace as required. Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST page 7-19. b0735a7x Figure 7-22. Check Stator AC Voltage Output 7-20 2002 Buell X1: Electrical...
Page 394 Examine stator leads for cracked or damaged insulation. half. Withdraw stator wiring (4) from grommet hole in left NOTE crankcase half. Remove stator (1). The rotor and stator can be replaced individually if either is damaged. 2002 Buell X1: Electrical 7-21...
Page 395 Connect battery cables, positive cable ﬁrst. 10. Test charging system. See 7.6 CHARGING SYSTEM. 7-22 2002 Buell X1: Electrical...
Page 396 Secure wire to frame with new cable straps. Install fuel tank. See 4.37 FUEL TANK. Connect negative battery cable to battery terminal. Install seat. See 2.40 SEAT. Test charging system. See 7.6 CHARGING SYSTEM. 2002 Buell X1: Electrical 7-23...
Page 397: Battery Cables
Connect positive cable to positive (+) battery termi- nal using bolt (metric) and nut. Connect negative cable to negative (-) battery termi- nal using bolt (metric) and nut. Tighten terminal bolts to 60-96 in-lbs in-lbs (7-11 Nm). 7-24 2002 Buell X1: Electrical...
Page 398 Attach negative cable to frame below oil tank. Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Nut with Washer (metric) Positive Battery Cable Figure 7-30. Positive Battery Cable (Protective Boot Not Shown) 2002 Buell X1: Electrical 7-25...
Page 399: Battery
HOME BATTERY 7.10 GENERAL Warning All Buell batteries are permanently sealed, maintenance-free, Label valve-regulated, lead/calcium and sulfuric acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.
Page 400: Disconnection And Removal
Remove battery strap locknut (metric). Unhook battery strap from frame near negative terminal. Inspect the battery case for cracks or leaks. Cut cable strap holding oxygen sensor connector to bat- tery. Remove battery from right side. 2002 Buell X1: Electrical 7-27...
Page 401: Safety Precautions
Overheating may result in plate distortion, internal shorting, dryout or other damage. Perform a voltmeter test to determine the state of charge. See BATTERY TESTING. If battery needs to be charged, proceed to step 2. 7-28 2002 Buell X1: Electrical...
Page 402 Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (7-11 Nm). Apply a light coat of petroleum jelly or corrosion retar- dant material to both battery terminals. 2002 Buell X1: Electrical 7-29...
Page 403 (not freezing), dry place. See Fig- ure 7-35. Charge the battery every month if stored at temperatures below 60˚ F. (16˚ C). Charge the battery more frequently if stored in a warm area above 60˚ F. (16˚ C). 7-30 2002 Buell X1: Electrical...
Page 404: Headlamp
Figure 7-37. Headlamp Bulbs Remove headlamp housing from vehicle. Remove headlamp brackets. Remove front turn signals. See 7.13 TURN SIG- NALS. Remove four bolts (3) from weldnuts. Remove front forks and headlamp brackets (4). See 2.16 FRONT FORK. 2002 Buell X1: Electrical 7-31...
Page 405 Insert bulb. Close the wire retaining latch (1). Connect the headlamp bulb connector. NOTE When replacement is required, see your Buell dealer. Not using the speciﬁed bulb may cause charging system problems. Insert position lamp bulb (3). Connect ground wire (5).
Page 406: Tail Lamp
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.40 SEAT. 2002 Buell X1: Electrical 7-33...
Page 407: Turn Signals
Activate left turn signals using switch on left handle- bar. Front and rear left turn signals must ﬂash. Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. 7-34 2002 Buell X1: Electrical...
Page 408 Activate right turn signals using switch on left han- R/BK Signal dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. Figure 7-44. Rear Turn Signal Connections 6839 Lockwasher Turn Signal Cable Strap Figure 7-45. Rear Turn Signals 2002 Buell X1: Electrical 7-35...
Page 409: Turn Signal Flasher
Front and rear left turn sig- nals must ﬂash. Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. 7-36 2002 Buell X1: Electrical...
Page 410: Handlebar Switches
[24] along right side frame tube. Detach connector [24] from wiring har- ness. Cut as many cable straps as necessary to access clutch switch connector [95] along right side frame tube. Detach connector [95] from wiring harness. 2002 Buell X1: Electrical 7-37...
Page 411 Horn Attach connector [24] and, if necessary, connector [95} Figure 7-51. Left Handlebar Switches to wiring harness. Fasten wiring harness to frame with new cable straps. Install fuel tank. See 4.37 FUEL TANK 7-38 2002 Buell X1: Electrical...
Page 412 Headlamp should ﬂash HIGH beam for as long as the switch is pressed. Check left and right turn signals. Activate horn by pressing horn switch. Turn ignition key switch to OFF. Figure 7-53. Routing Handlebar Wires, Left 2002 Buell X1: Electrical 7-39...
Page 413: Speedometer Sensor
Bolt harness. Speedometer Sensor Figure 7-54. Speedometer Sensor b0670x2x Odometer Speedometer Sensor Reset LT BE/W Button Speedometer Sensor A B C Connector [65] Speedometer BK/Y BK/Y Instrument Connector [39] Tachometer Figure 7-55. Speedometer Sensor Wiring 7-40 2002 Buell X1: Electrical...
Page 414: Speedometer
[39] on the wiring harness. If necessary, replace speedometer wiring. Purge fuel line and remove fuel tank. See 4.37 FUEL TANK. Cut cable straps on wiring harness. Detach wires at plug connector. 2002 Buell X1: Electrical 7-41...
Page 415 Position dash panel on instrument sup- port clamp. Attach dash panel using two screws (1) to hold panel to clamp. Tighten screws to 4-5 ft-lbs (5-7 Nm). Attach windscreen to mounting brackets using four screws and washers. 7-42 2002 Buell X1: Electrical...
Page 416: Tachometer
Purge fuel line and remove fuel tank. See 4.37 FUEL TANK. Cut cable straps on wiring harness. See Figure 7- Detach wires at plug connector. NOTE Tachometer and speedometer wiring share a common con- nector [39] on the wiring harness. 2002 Buell X1: Electrical 7-43...
Page 417 Attach dash panel using two screws (1) to hold panel to clamp. Tighten screws to 4-5 ft-lbs (5-7 Nm). Attach windscreen to mounting brackets using four screws and washers. Figure 7-63. Tachometer Wiring Connector Locations (Approximate) 7-44 2002 Buell X1: Electrical...
Page 418: Speedometer Performance Check
1134 1474 press CLEAR to cancel and enter the new fre- CAN, quency. Press ENTER to begin and reverify. 1350 1755 JPN, NZ NOTE The speedometer should be accurate within 0-4 MPH (0- 6.5 KPH). 2002 Buell X1: Electrical 7-45...
Page 419 Rotate the motorcycle’s rear wheel. If reading on speedometer tester changes as wheel is rotated, speedometer sensor is OK. If reading does not change, speedometer sensor is suspect. Install a known, good speedometer sensor and test again. 7-46 2002 Buell X1: Electrical...
Page 420 Go to Speedometer Test: Chart Replace Place jump wire across boot. leads to reset switch on back of speedometer. 6002 Does display toggle between modes? Replace Replace reset switch. speedometer. 6001 6020 2002 Buell X1: Electrical 7-47...
Page 421 Go to If necessary, remove speedometer sensor Speedometer Test: and check for accumulation of debris. If Chart debris is not present, replace sensor. If debris is present, clean sensor and repeat test. Replace if necessary. 7-48 2002 Buell X1: Electrical...
Page 422 6008 plug wires where insulation may be damaged. Does damage exist? Repair as Check speedometer speed necessary. sensor. Clean or replace sen- sor as required. Retest. 6016 Problem solved? System OK. Replace speedometer. 6029 6024 2002 Buell X1: Electrical 7-49...
Page 423: Tachometer Performance Check
If testing LO range, press 1 or 3. factor If testing CEN range, press 4 or 6. NOTE If testing HI range, press 7 or 9. All tachometer accuracy tolerances were taken at 68°-77° F (20-25° C). 7-50 2002 Buell X1: Electrical...
Page 424: Horn
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.40 SEAT. 2002 Buell X1: Electrical 7-51...
Page 425 If horn is faulty, replace unit as an assem- bly. The horn is not repairable. If battery voltage is not present, either horn switch or wiring to horn is faulty. If horn switch is faulty, replace left handlebar switch. See 7.15 HANDLE- SWITCHES. 7-52 2002 Buell X1: Electrical...
Page 426: Neutral Indicator Switch
Install sprocket cover. See 2.30 SPROCKET COVER. 10. Adjust secondary drive belt tension. See 1.11 DRIVE Remove transmission sprocket nut (5) from main drive gear shaft (3). See 6.7 TRANSMISSION CASE. BELT DEFLECTION. 2002 Buell X1: Electrical 7-53...
Page 427: Fuses And Circuit Breakers
HOME FUSES AND CIRCUIT BREAKERS 7.23 GENERAL b0769x7x Buell motorcycles feature two components which protect the electrical system. Fuses The fuse block is in the trunk, under the seat. Figure 7-72. The ignition (4) fuse is rated at 20 amps.
Page 428: Electrical Connectors
Under left handlebar controls [134] Bank Angle Sensor 3-place connector Under tail section, left side [137] Oxygen Sensor 1-place connector Under battery tray, right side Rear Brakelight Switch 2 blade connectors Behind battery, right side 2002 Buell X1: Electrical 7-55...
Page 429: Deutsch Electrical Connectors
If the secondary locking wedge does not slide into the installed position easily, verify that all terminals are fully installed in the socket housing. The lock indicates when terminals are not properly installed by not entering its fully installed position. 7-56 2002 Buell X1: Electrical...
Page 430 Close and squeeze crimp tool. hole of locking bar. contacts locking bar. Locking bar Raise locking bar and Inspect quality of core and remove contact. insulation crimps. Core Crimp Insulation Crimp x0007b7x Figure 7-76. Deutsch Crimping Procedure 2002 Buell X1: Electrical 7-57...
Page 431: Amp Multilock Electrical Connectors
An AMP TERMINAL CRIMP TOOL (Part No. HD-41609) is used to install Amp Multilock pin and socket terminals on wires. If new terminals must be installed, see CRIMPING INSTRUCTIONS. Secondary Lock Open Latch Pin Housing Pin Terminal Figure 7-78. Pin Housing 7-58 2002 Buell X1: Electrical...
Page 432 Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place. Secure wiring harness with new cable straps. Secondary Lock (open) Pin Housing Pin Terminal Figure 7-80. Pin Terminals 2002 Buell X1: Electrical 7-59...
Page 433 Close squeeze crimp tool. b0239x7x Pin Terminal Raise locking bar and remove contact Socket Terminal Insulation Crimp Tail Core Crimp Tail Figure 7-82. Amp Multilock Crimping Procedure Locking Groove Bar Tang Slot Figure 7-81. Crimps 7-60 2002 Buell X1: Electrical...
Page 434 HORN YW/BK R/GY TN/GN FLASHER R/BK GY/O TN/GN R G Y BK/R R/BK BATTERY STATOR GY/O KEY SWITCH [30] GY/O TN/W TN/W W/BK [62] [61] RELAY FUSE BLOCK BLOCK Figure 7-83. 2001 X1 Wiring Diagram 2002 Buell X1: Electrical 7-61...
Page 435 [33] HORN YW/BK R/GY TN/GN FLASHER R/BK GY/O TN/GN R GY BK/R R/BK BATTERY STATOR GY/O KEY SWITCH [30] GY/O TN/W TN/W W/BK [62] [61] RELAY FUSE BLOCK BLOCK Figure 7-83. 2001 X1 Wiring Diagram 2002 Buell X1: Engine 7-61...
Page 436 Table Of Contents SUBJECT PAGE NO. Appendix A-Tools ..........Appendix B-Metric Conversions .
Page 437 2002 BUELL X1 SERVICE MANUAL Part Number 99490-02Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendix...
Page 438 HOME APPENDIX A–TOOLS Part No. B-35316-5 12 Inch Bolt. Part No. B-42887 Brake Caliper Piston Remover Used with Part No. HD-39302. Part No. B-41174 Rear Wheel Support Stand and Part No. B-43721 Front Fork Seal Driver Part No. B-41174-2 Replacement Pad Part No.
Page 439 HOME Part No. B-59000A Pro Level Oil Gauge Part No. HD-25070 Robinair Heat Gun Part No. HD-01289 Rim Protectors Part No. HD-26792 Spark Plug Tester Part No. HD-21000 Tire Spreader Part No. HD-28700 Tire Bead Expander Part No. HD-23738 Vacuum Pump Part No.
Page 440 HOME Part No. HD-33223-1 Cylinder Compression Gauge Part No. HD-34623B Piston Pin Retaining Ring Installer/Remover Part No. HD-33416 Universal Driver Handle Part No. HD-34643A Shoulderless Valve Guide Seal Installer Part No. HD-33418 Universal Puller Forcing Screw Part No. HD-34723 Valve Guide Hone (8 mm) Part No.
Page 441 HOME Part No. HD-34731 Shoulderless Valve Guide Part No. HD-34813 Rowe Flywheel Rebuilding Jig Installation Tool Part No. HD-34736B Valve Spring Compressor Part No. HD-34816 Oil Pressure Switch Wrench Part No. HD-34740 Driver Handle and Remover. Used with Part No. HD-35102 Wrist Pin Bushing Hone (20 mm) HD-34643A and HD-34731.
Page 442 HOME Bdhgkjsbkdv ' ksjjlkn lk CYLINDER LEAKDOWN TESTER knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno[bho Bdhgkjsbkdv ' ksjjlkn lk knsdl hlno hslnsln nlslns finbp pklhb knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno[bho knsdl hlno hslnsln nlslns finbp pffb Bdhgkjsbkdv Majjlkn Nolk odlbndpob npdb ndbno[bho...
Page 443 HOME Part No. HD-37842A Inner/Outer Main Drive Gear Part No. HD-38361 Cam Gear Gauge Pin Set Needle Bearing Installer (0.108 in. (2.74 mm) Diameter) Part No. HD-38125-6 Packard Terminal Crimp Tool Part No. HD-38362 Sprocket Locking Link (Sealed and non-sealed connectors) Part No.
Page 444 HOME Part No. HD-39151 Shift Drum Retaining Ring Installer Part No. HD-39565 Engine Sound Probe Part No. HD-39301A Steering Head Bearing Part No. HD-39617 Inductive Amp Probe. Race Remover Use with HD-35500A. Part No. HD-39302 Steering Head Bearing Part No. HD-39621 Electrical Terminal Repair Kit Race Installer Part No.
Page 445 HOME Part No. HD-39621-28 Pin Terminal Remover Part No. HD-39823 Oil Filter Crusher, Large Part No. HD-39782 Cylinder Head Support Part No. HD-39847 Universal Ratcheting Tap/ Reamer Handle Part No. HD-39786 Cylinder Head Holding Fixture Part No. HD-39932 (Steel) or HD-39932-CAR (Carbide) Intake and Exhaust Valve Guide Reamer Part No.
Page 446 HOME Part No. HD-39965 Deutsch Terminal Crimp Tool Part No. HD-41025 Tool Organizational System Part No. HD-39969 Ultra-Torch UT-100 Part No. HD-41137 Hose Clamp Pliers Part No. HD-39978 Fluke 78 Multimeter (DVOM) Part No. HD-41155 VHS Video Shelf Part No. HD-39994 Paint Repair Kit Part No.
Page 447 HOME Part No. HD-41183 Heat Shield Attachment Part No. HD-41325 Scanalyzer Use with Part No. HD-25070. Part No. HD-41185 Hose Cutting Tool Part No. HD-41404 Test Connector Kit Part No. HD-41185-1 Oil Hose Cutter Part No. HD-41496 Main Drive Gear Seal Installer Part No.
Page 448 HOME Part No. HD-41609 Amp Terminal Crimp Tool Part No. HD-42311 Oil Filter Wrench Part No. HD-41675 Oil Pressure Sending Unit Wrench Part No. HD-42320 Piston Pin Remover/Installer Part No. HD-42310 Engine/Transmission Stand Part No. HD-42322 Piston Support Plate Made in USA PP-9606- 0001 Part No.
Page 449 HOME Part No. HD-42579 Sprocket Bearing/Seal Installer Part No. HD-43984 Crankshaft Locking Tool Part No. HD-42682 Breakout Box Part No. HD-44069 Timkin Snap Ring Remover/Installer Part No. HD-43646 Engine Stand Part No. HD-44358 Flywheel Fixture (2000 Models) Part No. HD-44069 Timkin Snap Ring Remover/Installer Part No.
Page 450 HOME Part No. HD-45206 Sprocket Shaft Seal/Spacer Installer Part No. HD-94800-26A Connecting Rod Bushing Reamers and Pilots Part No. HD-94547-101 Crankshaft Bearing Outer Race Part No. HD-94803-67 Rear Intake Camshaft Remover/Installer Bushing Reamer Part No. HD-94547-102 Drive Handle Part No. HD-94804-57 Rocker Arm Bushing Reamer (Used with HD-94547-100 and HD-94547-101) Part No.
Page 451 HOME Part No. HD-94812-87 Pinion Shaft Reamer Pilot. Part No. HD-95760-69A Bushing/Bearing Puller Tool Set. Use with HD-94812-1. Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD- 95770-69) and 10 (HD-95771-69) are optional. Part No. HD-95017-61 Large External Retaining Part No. HD-95952-33B Connecting Rod Ring Pliers Clamping Tool Part No.
Page 452 HOME Part No. HD-96295-65D Timing Mark View Plug. Part No. HD-96710-40B Crankcase Main Bearing Use with HD-33813. Lapping Tool Part No. HD-96333-51C Piston Ring Compressor Part No. HD-96718-87 Pinion Bearing Outer Race Lapping Kit Part No. HD-96550-36A Valve Lapping Tool Part No.
Page 453 HOME Part No. HD-96921-52A Oil Pressure Gauge Part No. HD-97292-61 Two Claw Puller Part No. HD-96940-52A Oil Pressure Gauge Adapter. Part No. HD-99500-80 Wheel Truing Use with HD-96921-52A. and Balancing Stand Part No. HD-97087-65B Hose Clamp Pliers Part No. J-5586 Transmission Shaft Retaining Ring Pliers A-16 Appendix A, Tools...
Page 454 HOME APPENDIX B–METRIC CONVERSIONS Table B-1. Metric Conversions MILLIMETERS TO INCHES INCHES TO MILLIMETERS (MM X 0.03937 = INCHES) (INCHES X 25.40 = MM) in. mm in. mm in. mm in. in. mm in. mm in. mm in. .0039 .9842 2.283 3.582 .001...
Page 455 WARNING meters, use the formulas given under the metric chart. For all The quality fasteners used on Buell motorcycles have other steel fasteners, use the values listed in one of the tables speciﬁc strength, ﬁnish and type requirements to perform below.

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