Buell 2002 X1 Handbook page 114

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ASSEMBLY/INSTALLATION
Muffler
1. If removed, install exhaust header.
2. See Figure 2-107. If removed, install Z-bracket.
a. Install rear muffler mounts and mount spacers on
swingarm mount block.
b. Attach Z-bracket with bolts, locknuts and washers.
Bolt heads install on opposite side of the swingarm
mount block from Z-bracket. Tighten bolts to 22-24
ft-lbs (30-33 Nm).
3. See Figure 2-105. If removed, attach front muffler sup-
port to crankcase.
a. Insert two front muffler mounts and mount spacer
into muffler support.
b. Install nuts and washers securing front muffler sup-
port to voltage regulator bracket and crankcase.
c. Attach header support mount to crankcase with two
upper bolts, washers and locknuts. Tighten bolts to
30-33 ft-lbs (41-45 Nm).
d. Lower and remove jack from under motorcycle.
4. Coat inside of muffler inlet with PERMATEX ULTRA-
COPPER HIGH TEMP RTV SILICON GASKET material.
NOTE
If necessary, use a fiber hammer to fit muffler on header.
5. Place a new muffler clamp over slotted end of muffler.
Place muffler and clamp on end of exhaust header. Snug
clamp but do not tighten.
11 1
WARNING
Before tightening muffler hardware, position muffler to
provide adequate clearance from rear shock absorber,
side stand spring post and rear tire. Failure to provide
adequate clearance during motorcycle operation could
result in death or serious injury.
6. See Figure 2-104. Position muffler and install to rear
mounting support and weldnuts in rear muffler straps
with two sets of bolts, washers and locknuts. Tighten
bolts to 22-24 ft-lbs (30-33 Nm).
7. See Figure 2-105. Secure muffler to header support
mount with bolt, locknut and washers. Tighten to 22-24
ft-lbs (30-33 Nm).
8. If only the muffler is being replaced, tighten muffler
clamp hardware to 40-45 ft-lbs (54-61 Nm) at this time. If
also installing the exhaust header, leave muffler clamp
loose.
Exhaust Header
NOTE
Tighten muffler hardware before exhaust header hardware.
1. See Figure 2-109. Install new exhaust port gaskets and
exhaust clamp retaining rings.
2. Slide exhaust header clamps over ends of exhaust
header.
3. See Figure 2-108. Slide exhaust header under frame by
positioning as shown, threading oxygen sensor wire
under frame.
2002 Buell X1: Chassis
WARNING
6813
Figure 2-108. Exhaust Header Positioning
b0676x2x Nut (4)
Clamp (2)
Exhaust
Header
Figure 2-109. Exhaust Header
6812
Figure 2-110. Exhaust Header Alignment
Gasket (2)
Retaining RIng (2)
2-67