Buell 2002 X1 Manuals

Manuals and User Guides for Buell 2002 X1. We have 3 Buell 2002 X1 manuals available for free PDF download: Service Manual, Handbook, Owner's Manual

Buell 2002 X1 Service Manual (462 pages)

Brand: Buell | Category: Motorcycle | Size: 16.58 MB

Maintenance 1

21
- Table of Contents
  21
- General
  23
  - Safe Operating Maintenance
    23
  - Repair and Replacement Procedures
    24
  - Lip Type Seals
    24
  - Hardware and Threaded Parts
    24
  - Instruments and Gauges
    24
  - Part Replacement
    24
  - Part Protection
    25
  - Cleaning Process
    25
  - Rust or Corrosion Removal
    25
  - Tool Safety
    25
  - Air Tools
    25
  - Ratchets and Handles
    26
  - Storage Units
    26
- Fluid Requirements
  27
  - Front Fork Oil
    27
  - Brake Fluid
    27
- Care of Molded-In-Color Body Panels
  33
- Ceramic Header
  34
- Battery
  35
  - Voltmeter Test
    35
  - Cleaning and Inspection
    35
- Engine Lubrication System
  37
- Brakes
  39
  - Rear Brake Pedal
    41
- Brake Pads and Rotors
  42
- Tires and Wheels
  43
  - Tire Inflation
    43
  - Wheel Bearings
    43
- Clutch
  44
- Drive Belt Deflection
  46
- Drive Belt and Sprocket
  48
- Primary Chain
  50
- Preload Adjustment
  51
- Suspension Damping Adjustments
  52
- Front Fork
  53
- Steering Head Bearings
  54
- Spark Plugs
  56
- Air Cleaner Filter
  57
- Throttle Cables
  58
- Ignition Timing
  59
- Handlebars
  61
- Headlamp
  62
- Storage
  63
- Troubleshooting
  64
  - Electrical System
    65
  - Fuel System
    65
Chassis 2

67
- Specifications
  69
  - Torque Values
    69
- Tire Specifications
  72
- Vehicle Identification Number
  73
- Wheels
  74
- Front Wheel
  76
- Rear Wheel
  79
- Checking Cast Rim Runout
  82
- Tires
  83
  - Wheel Balancing
    85
- Brakes
  86
- Front Brake Master Cylinder
  88
- Front Brake Caliper
  91
- Front Brake Line
  94
- Rear Brake Master Cylinder
  96
- Rear Brake Caliper
  99
- Rear Brake Line and Switch
  102
- Front Fork
  105
- Fork Stem and Bracket Assembly
  110
- Steering Head Lock
  112
- Swingarm
  113
- Rear Isolators
  118
- Rear Shock Absorber
  121
- Suspension Theory
  123
  - Spring Preload
    124
- Suspension Adjustments
  124
- Throttle Control
  127
- Clutch Control
  129
- Instrument Support
  131
- Handlebars
  132
- Exhaust System
  133
- Footrests
  137
- Sprocket Cover
  138
- Front Fender
  139
- Rear Fender
  140
- Belt Guards
  141
- Chin Fairing
  142
- Fuel Tank Cover
  143
- Air Scoop
  144
- Trunk
  145
- Tail Section
  146
- Windscreen
  149
- Seat
  150
- Side Stand
  151
Engine 3

153
- Specifications
  155
- Engine
  159
  - Engine Removal
    162
- Stripping Motorcycle for Engine Repair
  162
- Installing the Engine
  164
- Cylinder Head
  166
- Cylinder and Piston
  177
  - Boring and Honing Cylinder
    180
- Lubrication System
  185
  - Winter Lubrication
    185
- Oil Hose Routing
  186
- Oil Tank
  187
- Oil Pressure Indicator Switch
  188
- Crankcase Breathing System
  189
- Oiling System (Color Foldout)
  190
- Oil Pump
  191
- Oil Filter Mount
  194
- Hydraulic Lifters
  195
- Gearcase Cover and Cam Gears
  197
- Crankcase
  204
Fuel System 4

217
- Specifications
  219
- Dynamic Digital Fuel Injection
  221
- Diagnostic Introduction
  223
- Checking for Trouble Codes
  224
- Scanalyzer
  226
- Check Engine Lamp Diagnostics
  229
- Breakout Box
  231
- Wiggle Test
  232
- General Information
  233
- Initial Diagnostic Check
  233
- Check Engine Lamp Not Illuminated at Key on 4.10
  239
- Check Engine Lamp on Continuously
  242
- Engine Cranks but will Not Start
  245
- No ECM Power
  250
- Fuel Pressure Test
  253
- Idle Speed Control
  258
- Misfire
  259
- Trouble Code 11
  263
- Trouble Code 13
  267
- Trouble Code 14
  272
- Trouble Code 15
  276
- Battery Voltage
  280
- Trouble Code 16
  280
- Trouble Codes 23 and 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 and
  284
- Trouble Code 33
  291
- Trouble Code 35
  294
- Trouble Code 44
  297
- Trouble Codes 52, 53, 54 and 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28 Trouble Code 56
  301
- Electronic Control Module
  306
- Cam Position Sensor and Rotor
  308
- Ignition Coil
  312
- Oxygen Sensor
  314
- Engine Temperature Sensor
  315
- Bank Angle Sensor
  316
- Intake Air Temperature Sensor
  317
- Throttle Position Sensor
  318
- Fuel Tank
  319
- Fuel Tank Vent Valve
  322
- Inline Fuel Filter
  324
- Fuel Pump
  325
- Throttle Body and Intake Manifold
  327
- Air Cleaner
  331
- Evaporative Emissions Control-California Models
  333
Electric Starter 5

337
- Starter Relay
  340
- Wiring Diagrams
  340
- Starting System Diagnosis
  343
- Starter Activation Circuits
  345
- Diagnostics/Troubleshooting
  346
- Starter System Testing
  349
- Starter
  350
  - Testing Assembled Starter
    350
- Starter Solenoid
  357
Drive/Transmission 6

359
- Specifications
  361
- Primary Chain
  363
- Drive Belt
  366
- Clutch Release Mechanism
  368
- Primary Drive/Clutch
  370
- Transmission
  377
- Transmission Case
  379
- Shifter Forks and Drum
  381
- Mainshaft and Countershaft
  384
- Main Drive Gear
  390
- Access Door Bearings
  392
- Right Transmission Case Bearings
  393
- Transmission Installation and Shifter Pawl Adjustment
  394
Electrical 7

397
- Specifications
  399
- Ignition System
  401
- Ignition/Headlamp Key Switch
  403
- Spark Plug Cables
  405
- Starter Interlock
  406
- Charging System
  413
- Alternator
  419
- Voltage Regulator
  421
- Battery Cables
  422
- Battery
  424
  - Battery Testing
    424
  - Disconnection and Removal
    425
  - Safety Precautions
    426
- Headlamp
  429
- Tail Lamp
  431
- Turn Signals
  432
- Turn Signal Flasher
  434
- Handlebar Switches
  435
- Speedometer Sensor
  438
- Speedometer
  439
- Tachometer
  441
- Speedometer Performance Check
  443
- Tachometer Performance Check
  448
- Horn
  449
- Neutral Indicator Switch
  451
- Fuses and Circuit Breakers
  452
- Electrical Connectors
  453
- Deutsch Electrical Connectors
  454
- Amp Multilock Electrical Connectors
  456

Buell 2002 X1 Handbook (455 pages)

Brand: Buell | Category: Motorcycle | Size: 16.53 MB

Chassis 2

47
- General
  3
- Repair and Replacement Procedures
  4
- Lip Type Seals
  4
- Hardware and Threaded Parts
  4
- Instruments and Gauges
  4
- Part Replacement
  4
- Air Tools
  5
- Tool Safety
  5
- Rust or Corrosion Removal
  5
- Cleaning Process
  5
- Part Protection
  5
- Ratchets and Handles
  6
- Storage Units
  6
- Fluid Requirements
  7
- Care of Molded-In-Color Body Panels
  13
- Ceramic Header
  14
- Engine Lubrication System
  17
- Brakes
  19
  - Rear Brake Pedal
    21
  - Brake Pads and Rotors
    22
  - Tires and Wheels
    23
- Clutch
  24
  - Drive Belt Deflection
    26
  - Drive Belt and Sprocket
    28
- Primary Chain
  30
  - Preload Adjustment
    31
  - Suspension Damping Adjustments
    32
- Front Fork
  33
  - Steering Head Bearings
    34
  - Spark Plugs
    36
  - Air Cleaner Filter
    37
  - Throttle Cables
    38
  - Ignition Timing
    39
- Handlebars
  41
  - Electrical System
    43
- Fuel System
  43
  - Storage
    44
  - Troubleshooting
    45
  - Table of Contents
    47
- Tire Specifications
  51
- Vehicle Identification Number
  52
- Front Wheel
  55
- Rear Wheel
  58
  - Cleaning and Inspection
    59
- Checking Cast Rim Runout
  61
  - Wheel Balancing
    64
- Front Brake Master Cylinder
  67
- Front Brake Caliper
  70
- Front Brake Line
  73
- Rear Brake Master Cylinder
  75
- Rear Brake Caliper
  78
- Rear Brake Line and Switch
  81
- Fork Stem and Bracket Assembly
  89
- Steering Head Lock
  91
- Rear Isolators
  97
- Rear Shock Absorber
  100
- Suspension Theory
  102
  - Spring Preload
    103
- Suspension Adjustments
  103
- Throttle Control
  106
  - Clutch Control
    108
- Instrument Support
  110
- Exhaust System
  112
- Sprocket Cover
  117
- Front Fender
  118
- Rear Fender
  119
- Belt Guards
  120
- Chin Fairing
  121
  - Fuel Tank Cover
    122
- Air Scoop
  123
- Tail Section
  125
- Side Stand
  130
Engine 3

132
- Specifications
  133
  - Torque Values
    136
- 1.6 Engine
  140
- Stripping Motorcycle for Engine Repair
  140
- Installing the Engine
  142
- Cylinder Head
  144
- Cylinder and Piston
  155
  - Boring and Honing Cylinder
    158
- Lubrication System
  163
  - Winter Lubrication
    163
- Oil Hose Routing
  164
- Oil Tank
  165
- Oil Pressure Indicator Switch
  166
- Crankcase Breathing System
  167
- Oiling System (Color Foldout)
  168
- Oil Pump
  169
- Oil Filter Mount
  172
- Hydraulic Lifters
  173
- Gearcase Cover and Cam Gears
  175
- Crankcase
  182
Fuel System 4

195
- Specifications
  197
- Dynamic Digital Fuel Injection
  199
- Diagnostic Introduction
  201
- Checking for Trouble Codes
  202
- Scanalyzer
  204
- Check Engine Lamp Diagnostics
  207
- Breakout Box
  209
- Wiggle Test
  210
  - General Information
    211
- Initial Diagnostic Check
  211
- Fuel Pressure Test
  212
- Trouble Code 11
  212
- Trouble Code 13
  212
- Trouble Code 14
  212
- Trouble Code 15
  212
- Trouble Code 16
  212
- Trouble Code
  213
- Trouble Codes 23 and 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 and
  213
- Fuel Tank
  223
- Intake Air Temperature Sensor
  254
  - Battery Voltage
    258
  - Trouble Codes 24 and
    266
- Bank Angle Sensor
  275
- Electronic Control Module
  284
- Cam Position Sensor and Rotor
  286
- Ignition Coil
  290
- Fuel Tank
  297
- Fuel Tank Vent Valve
  300
- Inline Fuel Filter
  302
- Fuel Pump
  303
- Throttle Body and Intake Manifold
  305
- Air Cleaner
  309
- Evaporative Emissions Control-California Models
  311
Electric Starter 5

315
- Electric Starter System
  317
  - Wiring Diagrams
    317
  - Starter Relay
    317
- Starting System Diagnosis
  320
- Starter Activation Circuits
  322
- Diagnostics/Troubleshooting
  323
- Starter System Testing
  326
- Starter
  327
  - Testing Assembled Starter
    327
- Starter Solenoid
  334
Drive/Transmission 6

336
- Drive Belt
  342
- Clutch Release Mechanism
  344
- Primary Drive/Clutch
  346
- Transmission Case
  355
- Shifter Forks and Drum
  357
- Mainshaft and Countershaft
  360
- Main Drive Gear
  366
- Access Door Bearings
  368
- Right Transmission Case Bearings
  369
- Transmission Installation and Shifter Pawl Adjustment
  370
Electrical 7

373
- Specifications
  374
- Ignition System
  376
- Ignition/Headlamp Key Switch
  378
- Spark Plug Cables
  380
- Starter Interlock
  381
- Alternator
  388
- Charging System
  388
- Voltage Regulator
  388
- Battery Cables
  397
- Battery
  399
  - Battery Testing
    399
  - Voltmeter Test
    399
  - Disconnection and Removal
    400
  - Safety Precautions
    401
- Headlamp
  404
- Tail Lamp
  406
- Turn Signals
  407
- Turn Signal Flasher
  409
- Handlebar Switches
  410
- Speedometer Sensor
  413
- Speedometer
  414
- Tachometer
  416
- Speedometer Performance Check
  418
- Tachometer Performance Check
  423
- Horn
  424
- Neutral Indicator Switch
  426
- Fuses and Circuit Breakers
  427
- Electrical Connectors
  428
- Deutsch Electrical Connectors
  429
- Amp Multilock Electrical Connectors
  431

Buell 2002 X1 Owner's Manual (33 pages)

Lubrication System

Brand: Buell | Category: Engine | Size: 2.36 MB

Lubrication System
1
Changing Oil and Filter
1
Oil Hose Routing
2
Oil Tank
3
Oil Pressure Signal Light
4
Oil Pressure
4
Crankcase Breathing System
5
Oil Pump
7
Cleaning and Inspection
9
Hydraulic Lifters
11
Installation
12
Bushing Reaming
16
Pinion Shaft Bushing Installation (to Gear- Case Cover)
16
Cam Bushing Reaming (Crankcase)
17
Cam Bushing Reaming (Gearcase Cover)
17
Pinion Shaft Bushing Reaming (Gearcase Cover)
18
Lapping Engine Main Bearing Races
27
Crankcase Halves
29

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More Buell Manuals

Buell 2002 X1 Manuals

Buell 2002 X1 Service Manual (462 pages)

Table of Contents

Maintenance 1

Chassis 2

Engine 3

Fuel System 4

Electric Starter 5

Drive/Transmission 6

Electrical 7

Buell 2002 X1 Handbook (455 pages)

Table of Contents

Chassis 2

Engine 3

Fuel System 4

Electric Starter 5

Drive/Transmission 6

Electrical 7

Buell 2002 X1 Owner's Manual (33 pages)

Table of Contents

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