Buell 2002 X1 Handbook page 87

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CAUTION
The outer tube can move freely up and down on the slide
pipe. Always hold both the slide pipe and outer tube to
prevent damage to bushings and seals.
6. See Figure 2-57. Carefully place the slide pipe (17) into
the outer tube (8).
7. Move and tape or tie the dust seal (13) and stopper ring
(12) out of the way.
8. Using FORK SEAL DRIVER (Part No. B-43721), drive
the guide bushing (9) with the seal spacer (10) and oil
seal (11) into position in the outer tube (4). See
61.
9. See Figure 2-57. Remove any tape or ties and reinstall
the stopper ring (12) and a new dust seal (13).
10. Place the centering plate (15) onto the damper (14) and
insert the assembly into the slide pipe (17).
11. Clamp the axle holder in a vise with soft jaws or use a
shop towel. Replace the special washer (18) and center
bolt (19) (metric). Tighten the center bolt to 22-29 ft-lbs
(30-39 Nm).
NOTE
The recommended fork oil is hydraulic fork oil Type "E".
12. While supporting the fork, pour one-half of the recom-
mended amount of fork oil, 8 oz. (225 cc), into the fork
pipe.
13. Pump the piston rod and leg slowly at least 10 times,
about 6 in. (150 mm) strokes.
14. Place the piston rod and outer tube (8) in the full bot-
tomed position.
15. See Figure 2-62. Pour the recommended fork oil into the
slide pipe to a level between the maximum and minimum
limits. Additional information on setting oil levels can be
found under 1.16 FRONT
16. See Figure 2-63. Install the spring, with the taper side at
top, and the spring collar and spring joint.
17. See Figure 2-56. Place FRONT FORK SPRING COM-
PRESSOR (1) into position and press down on the
spring collar (2).
18. Set the spring seat stopper (3) between the spring collar
(2) and the locknut. Remove the FRONT FORK SPRING
COMPRESSOR.
19. See Figure 2-55. Apply oil to a new O-ring and install it
into position on the fork bolt. Install fork bolt. Tighten to
22-29 ft-lbs (30-39 Nm).
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
Figure 2-
FORK.
6958
1
1. Fork Seal Driver
2. Guide Bushing with Seal Spacer
3. Outer Tube
Figure 2-61. Fork Seal Driver
Figure 2-62. Oil Level Measurement
7097
Thin Taper
at Top
Figure 2-63. Spring Installation
2
3
b0666x2x
Oil Level
Maximum:
2.36 in. (60.0 mm)
Minimum:
4.33 in. (110.0 mm)
2002 Buell X1: Chassis