Buell 2002 X1 Handbook page 109

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ASSEMBLY/INSTALLATION
Clutch Cable-Lower
1. See Figure 2-97. Install O-ring (8) over cable end fitting
(9) of clutch cable lower section. Turn fitting clockwise to
install into primary cover (11). Tighten fitting to 3-9 ft-lbs
(4-12 Nm).
2. Fit coupling (16) over cable end. Place hook of ramp
around coupling button and rotate assembly counter-
clockwise until tang on inner ramp (15) fits in slot of pri-
mary cover (11).
3. Thread nut (5) on adjusting screw (12) until slot of screw
is accessible with a screwdriver. Fit nut hex into recess of
outer ramp (6) and turn adjusting screw counter-clock-
wise.
4. If not yet performed, route clutch cable to hand control.
a. See Figure 2-99. Route cable along left side of pri-
mary chaincase and up to clamp on front isolator tie
bar. Cable must not touch chin fairing.
b. Clamp should be on bottom left of bolt. Brass fitting
on cable should be approximately 3.0 in. (76 mm)
above clamp.
c. Continue above and behind lower triple clamp,
between right side of the steering head and left of
front brake line.
d. Route cable across front of upper triple clamp to
hand grip.
5. With clutch cable upper section connected to clutch
lever, check primary chain tension. Adjust if necessary.
See 1.13 PRIMARY CHAIN.
6. Adjust clutch. See 1.10
Clutch Hand Control
1. See Figure 2-98. Attach clutch clamp (5) as follows.
a. Slide clamp over handlebar.
b. Install left switchgear housing. See
BAR SWITCHES.
c. Place clamp next to switchgear housing. Fasten to
handlebar with screw (4) (metric). Tighten to 30-35
in-lbs (3-4 Nm).
d. Install a new left handgrip. See
BARS.
2. Connect end of clutch cable upper section to clutch han-
dlever. Position lever within clutch clamp.
3. Apply small amount of LOCTITE ANTI-SEIZE LUBRI-
CANT to bolt (2). Attach handlever with bolt (2) (metric)
and nut (6) (metric).
4. Attach clutch switch (7) with screw (8).
5. If not yet performed, route clutch cable to primary cover.
a. Route cable from hand grip across front of upper tri-
ple clamp.
b. 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
CLUTCH.
7.15 HANDLE-
2.27 HANDLE-
1. Clutch Handlever
2. Bolt (metric)
3. Mirror
4. Screw (metric)
5. Clutch Clamp
6. Nut (metric)
7. Clutch Switch
8. Screw
9. Clutch Cable
10. Cable Clamp
4
5
9
b0380x2x
Figure 2-98. Clutch Hand Control
8291
Clamp
Figure 2-99. Clutch Cable Routing, Lower
c. Continue through clamp on front isolator. Clamp
should be on bottom left of bolt. Brass fitting on
cable should be approximately 3.0 in. (76 mm)
above clamp.
d. See Figure 2-99. Route cable down left side of bike,
through clamp, along primary chaincase to clutch.
Cable must not touch chin fairing.
6. With clutch cable lower section connected to primary
cover, adjust clutch. See
3
1
2
6
8 7
10
Clutch
1.10 CLUTCH.
2002 Buell X1: Chassis