Buell 2002 X1 Handbook page 306

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4. Label and detach throttle cables.
a. Remove screw and throttle cable brackets from
throttle cables.
b. See Figure 4-101.
Through the slots (1, 2) in the side of the bracket (3),
remove both throttle cables.
c. Using needle nose pliers, pull the cable barrels from
attachment points (4, 5).
5. Detach wiring.
a. Disconnect throttle position sensor by lifting both
tabs on the connector while rocking the connection
and pulling apart.
b. If removing throttle body and intake manifold as an
assembly, disconnect fuel injectors. Depress wire
form on connector and use a rocking motion to
detach electrical connectors from injectors.
6. If only removing throttle body, remove two screws (6)
(metric). Detach hook on rail from tab on intake manifold
(7) and slide throttle body out.
7. See Figure 4-100. Remove assembly from motorcycle.
a. On primary cover side, loosen but do not remove the
two front and rear intake flange screws (13). For
best results use a 1/4 inch ball Allen bit with an end
driver at least 4 inches long.
b. On gearcase cover side, remove both intake flange
screws from cylinder heads.
c. Slide the throttle body and manifold assembly out
from the right side of the bike frame.
8. Remove intake flanges (14) from manifold. Remove and
discard seals (15).
REPAIR
Throttle Position Sensor
See 4.36 THROTTLE POSITION SENSOR
installation and calibration procedures.
Fuel Injectors - Removal
1. Remove throttle body and intake manifold. See
THROTTLE BODY AND INTAKE
2. See Figure 4-102. Separate fuel rail assembly (3) from
throttle body manifold.
a. Remove both injector clips (4).
b. Remove screw (3) (metric) that holds the fuel rail to
the manifold.
c. Separate fuel rail from injectors (1, 2) by gently rock-
ing the fuel rail and pulling it away from the injectors.
4-110
Increase throttle cable freeplay.
for removal,
MANIFOLD.
6942
1
3
5
1. Throttle Control Cable Slot
2. Idle Control Cable Slot
3. Bracket
4. Idle Control Cable Attachment
5. Throttle Control Cable Attachment
6. Screws (2) (metric)
7. Hook and Tab
Figure 4-101. Throttle Cable Bracket (Typical)
6765
4
1
1. Front Fuel Injector
2. Rear Fuel Injector
3. Fuel Rail Assembly and Screw (metric)
4. Clip (2)
5. Fuel Inlet
Figure 4-102. Fuel Injectors
3. Remove fuel injectors (1, 2) from manifold by gently rock-
4.41
ing and pulling it away from the manifold.
Do not use any injector that has damaged or deformed
O-rings. Damaged O-rings may leak gasoline. Gasoline is
extremely flammable and highly explosive. Use of dam-
aged O-rings could result in death or serious injury.
4. Inspect all injector O-rings for cuts, tears or general dete-
rioration. Replace O-rings if they have been damaged or
have taken a definite set.
2
4
7
6
5
4
2
3
1 1
WARNING WARNING
2002 Buell X1: Fuel System