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Manual Therapy For The Cranial Nerves Barral, Digital Manual Husqvarna Te 510, Volvo Vida Workshop Manual, Hvca Guide To Good Practice Dw 145, Ih 1300 Sickle Mower Manual Reload to refresh your session. Reload to refresh your session. B-35316-5 12 Inch Bolt. Part No. B-42887 Brake Caliper Piston Remover Used with Part No. HD-39302. Part No. B-41174 Rear Wheel Support Stand and Part No. B-43721 Front Fork Seal Driver Part No. B-41174-2 Replacement Pad Part No. HD-25070 Robinair Heat Gun Part No. HD-01289 Rim Protectors Part No. HD-26792 Spark Plug Tester Part No. HD-21000 Tire Spreader Part No. HD-28700 Tire Bead Expander Part No. HD-23738 Vacuum Pump Part No. HD-33416 Universal Driver Handle Part No. HD-34643A Shoulderless Valve Guide Seal Installer Part No. HD-33418 Universal Puller Forcing Screw Part No. HD-34723 Valve Guide Hone (8 mm) Part No. HD-34813 Rowe Flywheel Rebuilding Jig Installation Tool Part No. HD-34736B Valve Spring Compressor Part No. HD-34816 Oil Pressure Switch Wrench Part No. HD-34740 Driver Handle and Remover. Used with Part No. HD-35102 Wrist Pin Bushing Hone (20 mm) HD-34643A and HD-34731. HD-38361 Cam Gear Gauge Pin Set Needle Bearing Installer (0.108 in. (2.74 mm) Diameter) Part No. HD-38125-6 Packard Terminal Crimp Tool Part No. HD-38362 Sprocket Locking Link (Sealed and non-sealed connectors) Part No. HD-39565 Engine Sound Probe Part No. HD-39301A Steering Head Bearing Part No. HD-39617 Inductive Amp Probe. Race Remover Use with HD-35500A. Part No. HD-39302 Steering Head Bearing Part No. HD-39621 Electrical Terminal Repair Kit Race Installer Part No. HD-39823 Oil Filter Crusher, Large Part No. HD-39782 Cylinder Head Support Part No. HD-39786 Cylinder Head Holding Fixture Part No. HD-39932 (Steel) or HD-39932-CAR (Carbide) Intake and Exhaust Valve Guide Reamer Part No. HD-41025 Tool Organizational System Part No. HD-39969 Ultra-Torch UT-100 Part No. HD-41137 Hose Clamp Pliers Part No. HD-39978 Fluke 78 Multimeter (DVOM) Part No.
HD-41155 VHS Video Shelf Part No. HD-39994 Paint Repair Kit Part No. HD-41325 Scanalyzer Use with Part No. HD-25070. Part No. HD-41185 Hose Cutting Tool Part No. HD-41404 Test Connector Kit Part No. HD-41185-1 Oil Hose Cutter Part No. HD-41496 Main Drive Gear Seal Installer Part No. HD-42311 Oil Filter Wrench Part No. HD-41675 Oil Pressure Sending Unit Wrench Part No. HD-42322 Piston Support Plate Made in USA PP-9606- 0001 Part No. HD-43984 Crankshaft Locking Tool Part No. HD-42682 Breakout Box Part No. HD-43646 Engine Stand Part No. HD-44358 Flywheel Fixture (2000 Models) Part No.HD-94800-26A Connecting Rod Bushing Reamers and Pilots Part No. HD-94547-101 Crankshaft Bearing Outer Race Part No. HD-94547-102 Drive Handle Part No. HD-94804-57 Rocker Arm Bushing Reamer (Used with HD-94547-100 and HD-94547-101) Part No. Use with HD-94812-1. Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD- 95770-69) and 10 (HD-95771-69) are optional. Part No. HD-95017-61 Large External Retaining Part No. HD-95952-33B Connecting Rod Ring Pliers Clamping Tool Part No. Lapping Tool Part No. HD-96333-51C Piston Ring Compressor Part No. HD-96718-87 Pinion Bearing Outer Race Lapping Kit Part No. HD-96550-36A Valve Lapping Tool Part No. HD-97292-61 Two Claw Puller Part No. HD-96940-52A Oil Pressure Gauge Adapter. Part No. HD-99500-80 Wheel Truing Use with HD-96921-52A.HD-97087-65B Hose Clamp Pliers Part No. J-5586 Transmission Shaft Retaining Ring Pliers A-16 Appendix A, Tools. Do not lift heavy parts by hand. A hoist ter, have a Buell dealer perform the service operations listed and adjustable lifting beam or sling are needed to remove Table 1-2. Part Replacement Bearings do not usually need to be removed. Only remove bearings if necessary. Always replace worn or damaged parts with new parts. 2002 Buell X1: Maintenance. Should you need to convert from U.S. descending order, are 20W-50, 15W-40 and 10W-40.
HD-41215) Use the proper grade of oil for the lowest temperature expected before the next oil change. HD 99855-89) Oil and brake lines (Section 2 and 3) Check for leaks and loose connections. To wash blue ceramic header, follow the instructions below: Rinse surface with water. Remove any oxidation. 12.0 Inspect the battery screws, clamps and cables for break- 11.8 age, loose connections and corrosion. Clean clamps. 2002 Buell X1: Maintenance 1-13. Tighten to 40 in-lbs (4.5 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Secure oxygen sensor connector with new cable straps. Install seat. See 2.40 SEAT. 1-14 2002 Buell X1: Maintenance. KEEP BRAKE Stand motorcycle upright.Front brake caliper bleeder valve-Figure 1-8. 2002 Buell X1: Maintenance 1-17. Tighten screws on front master cylinder reservoir to 9-13 in-lbs (1.0-1.5 Nm). Tighten cap on rear master cylinder reservoir securely. Remove cover from molded-in-color surfaces and right handlebar switches. 1-18 2002 Buell X1: Maintenance. Check rear brake pedal height. Excessive play or roughness indicates worn bearings. Replace bearings in sets only. 2002 Buell X1: Maintenance 1-21. Tighten in a crosswise pattern to 7-9 ft-lbs (10-12 Nm). Fluid Level 1-22 2002 Buell X1: Maintenance. Tighten in a cross- wise pattern to 7-9 ft-lbs (10-12 Nm). Figure 1-20. Adjusting Clutch Free Play Check clutch cable free play. See Step 6 above. 2002 Buell X1: Maintenance 1-23. Install drive support arm, sprocket cover and chin fairing. 2.30 SPROCKET COVER. 1-24 2002 Buell X1: Maintenance. Tighten axle nut (metric) to 66-73 ft-lbs (90-99 Nm). Locknut Adjusting Nut Figure 1-24. Axle Adjuster Bolt, Right Side Shown 2002 Buell X1: Maintenance 1-25. Replace belt and transmis- sion sprocket. Replace belt if either condition exists. 1-26 2002 Buell X1: Maintenance. Adjusting Screw Counterclockwise (outward) to increase free play. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Figure 1-28.
Measuring Primary Chain Adjustment 1-28 2002 Buell X1: Maintenance. Wipe excess grease off of shock absorber. NOTE When preload is increased, both compression and rebound damping should be increased. If preload is decreased, both compression and rebound damping should be decreased. 2002 Buell X1: Maintenance 1-29. Rear Shock Compression and Rebound Front Rebound Damping Adjustments Front 1.25 Compression Rear Rebound Rear 2.25 0.25 0.75 Compression 1-30 2002 Buell X1: Maintenance. Standard Oil Level 3.15 in. 80 mm Assemble and install forks. See 2.16 FRONT FORK. Maximum Oil Level 4.333 in. 110 mm Minimum Oil Level 2.36 in. 60 mm 2002 Buell X1: Maintenance 1-31. Checking Steering Head Bearings 1-32 2002 Buell X1: Maintenance. Steering Head Assembly 2002 Buell X1: Maintenance 1-33. Gap should be 0.038-0.043 in. (0.97-1.09 mm). 1-34 2002 Buell X1: Maintenance. Install long screw and nylon washer (2). Tighten to 27-29 in-lbs (3.1-3.3 Nm). Install two screws and nylon washers (1) to secure air cleaner cover. Tighten to 27-29 in-lbs (3.1-3.3 Nm). 2002 Buell X1: Maintenance 1-35. Regular idle speed is 850-1050 RPM. Set idle speed using 11. Install air cleaner assembly. See 4.42 AIR CLEANER. idle adjustment screw (4) shown in Figure 1-45. 1-36 2002 Buell X1: Maintenance. HD-42682) to electronic control module. Attach male gray connector on BREAKOUT BOX to wiring harness.Check steering motion range to both fork stops. Handle- bars should not make contact with the front forks or fuel tank cover. If handlebar needs further adjustment, repeat adjustment beginning with Step 1. 2002 Buell X1: Maintenance 1-39. At the same time, turn headlamp right or left to direct light beam straight ahead. Tighten both adjuster screws (metric) to 5-7 ft-lbs (7-10 Nm). 1-40 2002 Buell X1: Maintenance. This work should be performed by your local Buell dealer fol- lowing Service Manual procedures. WARNING WARNING Fill fuel tank and add a gasoline stabilizer.
Smokes Excessively Shifter engaging parts (inside transmission) badly worn Piston rings badly worn or broken.Shifter forks bent. Valve guides worn. Damaged gears. 2002 Buell X1: Maintenance 1-43. Brake rotor badly worn or warped. Brake pads dragging or excessive braking (brake fades due to heat buildup).NOTE Figure 2-3. Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle. Figure 2-2. Abbreviated V.I.N. Location Manufacturer: Buell Motorcycle Company Type Designation-Lightning X1. Damper tubes. Check for leaks. See 2.16 FRONT FORK. Shock absorbers. Check damping action and mounts. See 1.15 SUSPENSION DAMPING ADJUSTMENTS. Swingarm bearings. Check for looseness. See 2.19 SWINGARM. 2002 Buell X1: Chassis. Never replace just one brake pad. Fail- ure to install brake pads as a set could result in death or serious injury. Inspect brake rotor and pads. See 1.8 BRAKE PADS ROTORS. 2002 Buell X1: Chassis. CAST RIM RUNOUT. Balance tire. See 2.8 TIRES, Adjustment. 2002 Buell X1: Chassis. Tighten the four front axle pinch screws (2) (metric) to 13-15 ft-lbs (18-20 Nm). Install front brake caliper. See 2.11 FRONT BRAKE CALIPER. 2-10 2002 Buell X1: Chassis. Bearings (2) 11. Right Axle Spacer 12. Washer 13. Lockwasher 14. Axle Nut (metric) 15. Belt Sprocket 16. Washer (5) 17. Bolt (5) Figure 2-9. Rear Wheel 2002 Buell X1: Chassis 2-11. Tighten to 35-40 ft-lbs (48-54 Nm). NOTE: PM Wheel option uses a nut.Axle, Right Side 2002 Buell X1: Chassis 2-13. Checking Cast Rim Radial Runout 2-14 2002 Buell X1: Chassis. They are not interchangeable. Use front tire ONLY for a front tire. Check rim bead side runout. See 2.7 CHECKING CAST RUNOUT. Install tire and check again for tire tread lateral runout. 2-16 2002 Buell X1: Chassis. Allow eight hours for adhesive to cure completely before using wheel. 2002 Buell X1: Chassis 2-17. Depress piston assembly and remove internal snap ring Figure 2-22. Front Master Cylinder (3).
Discard snap ring. Figure 2-25. Remove piston assembly (1-4) from front master cylinder. 2-20 2002 Buell X1: Chassis. Piston Tighten to 7-13 in-lbs (1-2 Nm). Boot Snap Ring Test switch action. Tang on switch must release when hand lever is moved. Figure 2-25. Piston Assembly 2002 Buell X1: Chassis 2-21. Bleed brake system. See BRAKES. Discard O-rings. Check bleeder valve (4) (metric). Remove and replace if damaged. Pad Hanger Pin (metric) Pad Spring Screws (4) (metric) Figure 2-30. Pad Spring (Typical) 2002 Buell X1: Chassis 2-23. Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury. 2-24 2002 Buell X1: Chassis. Figure 2-36. Connect brake line to caliper using two new banjo washers (7) and banjo bolt (6). Loosely install bolt into caliper. 2-26 2002 Buell X1: Chassis. Install bleeder valve if removed.Turnbuckle (2). Discard snap ring. 12. Screw Remove piston assembly (4) from master cylinder body. 13. Remote Reservoir Figure 2-39. Rear Master Cylinder Assembly 2-28 2002 Buell X1: Chassis. Tighten to 16-20 ft-lbs (22-27 Nm). 2002 Buell X1: Chassis 2-29. Blow ROTORS. out drilled passages and bore with a clean air supply. Do not use a wire or similar instrument to clean drilled pas- sages. 2002 Buell X1: Chassis 2-31. Tighten to 18- 22 ft-lbs (24-30 Nm) Install small caliper screw (6) (metric). Tighten to 14.5-18 ft-lbs (20-24 Nm). Brake Caliper Piston Remover Adaptor Piston Figure 2-47. Removing Rear Brake Caliper Piston 2-32 2002 Buell X1: Chassis. Depress rear brake pedal several times to set brake pads to proper operating position within caliper. NOTE: Removing inner fender TORX screw and plastic washer will assist in tightening banjo bolt. If TORX screw and plastic washer are removed, tighten to 72-96 in-lbs (8-11 Nm) when installing. 2002 Buell X1: Chassis 2-35. Clamp the axle holder in a vise with soft jaws or use a shop towel.
Remove the center bolt (19) (metric) and the special washer (18). 2002 Buell X1: Chassis 2-37. Front Fork Assembly 2-38 2002 Buell X1: Chassis. Coat the slide bushing (6) and the guide bushing (1) with fork oil. 2002 Buell X1: Chassis 2-39. Figure 2-63. Spring Installation 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 2002 Buell X1: Chassis. Align headlamp. See 1.23 HEADLAMP. Adjust front forks to rider preferences. See 1.15 SUS- 2.0 in. PENSION DAMPING ADJUSTMENTS. (50.8 mm) Figure 2-65. Aligning Front Forks 2002 Buell X1: Chassis 2-41. Replace if necessary. Figure 2-66. Fork Stem 2-42 2002 Buell X1: Chassis. Figure 2-68. Fork Stem Clamp Screw Make sure the fork stem turns freely, then tighten the fork stem clamp screw (3). 2002 Buell X1: Chassis 2-43. Insert ignition key in lock. Turn key clockwise while pushing in. Remove key and verify that steering head is locked. Unlock steering head by inserting key and turning key counterclockwise. 2-44 2002 Buell X1: Chassis. Replace if REMOVER (Part No. HD-39301A) and UNIVERSAL damaged. DRIVER HANDLE (Part No. HD-33416). 2-46 2002 Buell X1: Chassis. Check swingarm preload using a scale as shown in Fig- ure 2-78.Lower motorcycle onto lift.Axle Adjuster Bolt, Right Side Shown 2-48 2002 Buell X1: Chassis. Tighten screws to 8-10 ft-lbs (11-14 Nm). 2002 Buell X1: Chassis 2-51. Rear Shock Absorber 2-54 2002 Buell X1: Chassis. Many variables affect motorcycle handling under different circumstances. Approach all changes carefully and consult Table 2-9. b0558xox Compression Adjuster Figure 2-90. Preload and Compression Damping Adjustment 2002 Buell X1: Chassis 2-55. Your Buell dealer can assist you if necessary. Rear Rebound Rear ADJUSTMENTS 2.25 0.25 0.75. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings.
Lack of tire feedback. Increase compression damping. Tire slides. Decrease compression damping. 2002 Buell X1: Chassis 2-57. Screw (short, top) Cable Adjusters (2) Idle Control Cable Throttle Control Cable with Molded End Front Housing Screw (Long, Bottom) Ferrules Cable Wheel Rear Housing 10. Locating Pin Figure 2-92. Cable Connections 2002 Buell X1: Chassis 2-59. Install air cleaner assembly. See 4.42 AIR CLEANER. Figure 2-95. Throttle Body Routing 8204 Throttle Cable Clamps Screw Arrow (Up) Figure 2-96. Throttle Cable Clamps 2-60 2002 Buell X1: Chassis. Clutch Cable End 11. Primary Cover 12. Clutch Adjusting Screw Assembly 13. Retaining Ring 14. Quad Ring 15. Inner Ramp 16. Coupling Figure 2-97. Clutch Release Mechanism 2002 Buell X1: Chassis 2-61. Route cable between right side of the steering head and left of front brake line. 2-62 2002 Buell X1: Chassis. Secure with four catches. Figure 2-100. Install both instruments. See 7.17 SPEEDOMETER 7.18 TACHOMETER. Attach windscreen using four screws and washers. 2002 Buell X1: Chassis 2-63. Install front brake master cylinder. See 2.10 FRONT BRAKE MASTER CYLINDER. Attach windscreen using four screws and washers. Check steering motion range to both fork stops. See 1.22 HANDLEBARS. 2-64 2002 Buell X1: Chassis. Figure 2-107. Remove exhaust header clamps (22), Jack exhaust clamp retaining rings (23) and exhaust port gas- kets (24) from exhaust header. Figure 2-106. Supporting Motorcycle with Jack 2002 Buell X1: Chassis 2-65. Exhaust System 2-66 2002 Buell X1: Chassis. Slide exhaust header clamps over ends of exhaust header. Figure 2-108. Slide exhaust header under frame by positioning as shown, threading oxygen sensor wire under frame. 2002 Buell X1: Chassis 2-67. Secure wiring and sensor with new cable ties. Install chin fairing. See 2.34 CHIN FAIRING. 2-68 2002 Buell X1: Chassis. Install washer (2) and retaining ring (1) to pin (3). Make sure retaining ring engages groove in pin. 2002 Buell X1: Chassis 2-69.
Sprocket Cover 2-70 2002 Buell X1: Chassis. Front Fender 2002 Buell X1: Chassis 2-71. Tighten bolts to 13- 16 ft-lbs (18-22 Nm).Rear Fender 2-72 2002 Buell X1: Chassis. Belt Guard and Stone Guard Installation b0729x2x Swingarm Screw (2) Washer (2) Lower Belt Guard Stone Guard Wellnut (2) Figure 2-118. Stone Guard and Belt Guard Mounting 2002 Buell X1: Chassis 2-73. If contact occurs, adjust clutch cable clamp. Bolt 8303 Washer Rubber Washer Chin Fairing Figure 2-121. Chin Fairing, Right Side Bolt and Washer Chin Fairing Clutch Cable Shift Lever Bolt, and Washer Figure 2-119. Chin Fairing, Left Side 2-74 2002 Buell X1: Chassis. Fuel Tank Cover 2002 Buell X1: Chassis 2-75. Figure 2-125. Install screw, washer, and nut to 6978 attach air scoop (1) to clamp (3). Air Scoop Clamp Screw and Washer Figure 2-125. Air Scoop Clamp 2-76 2002 Buell X1: Chassis. License Plate Bracket Screw and Washer (2) Figure 2-127. Data Link Location 2002 Buell X1: Chassis 2-77. Tilt license plate bracket (3) forward to remove. Figure 2-132. Remove two allen bolts (15), washers (3) and nuts (10) to detach seat lock (11) from tail sec- tion (14). 2-78 2002 Buell X1: Chassis. Nut (4) Washer (6) 19. Washer (4) Bracket, License Plate 20. Screw (4) 10. Nut (2) 11. Lock Assembly b0664x2x Figure 2-132. Tail Section 2002 Buell X1: Chassis 2-79. Figure 2-134. Install two screws and nylon washers on each side. Tighten securely. Figure 2-134. Windscreen, Right Side 2002 Buell X1: Chassis 2-81. ATTACHMENT POINTS CAUTION Helmet hook will not prevent helmet theft. See your Buell dealer for helmet locking solutions. Figure 2-136. Two metal hooks, cables and locktabs on the tail section serve as helmet holders. To store helmet, place cable through helmet D-ring. B- Figure 2-139. Side Stand Dragger Wear Limit 41174). With side stand retracted, there should be 0.5 in. (12.7 mm) clearance between side stand and swingarm at the closest point of contact. 2002 Buell X1: Chassis 2-83.
Hydraulic lifters and pushrods cleaner air in our environment. Head gasket leak Same reaction as valve trouble. 2002 Buell X1: Engine. CAUTION After completing the compression test(s), make sure that the throttle plate is in the closed position before starting engine. Engine will start at an extremely high RPM if throttle plate is left open. 2002 Buell X1: Engine. See Figure 3-2. Place a wooden cradle underneath the inders may be removed. See 3.5 CYLINDER HEAD. crankcase. 2002 Buell X1: Engine. Insert bolt through tie bar front isolator, and frame. Secure with nut and washer. 24. Continue with the steps listed under ENGINE INSTALLA- Tighten to 30-33 ft-lbs (41-45 Nm). TION AFTER CYLINDER HEAD REPAIR. 3-10 2002 Buell X1: Engine. Remove both push rod covers and hydraulic lifters. See 3.15 HYDRAULIC LIFTERS. 15. Repeat the above procedure for the other cylinder head. Figure 3-9. Front Isolator Mount and Tie Bar 2002 Buell X1: Engine 3-13. Repeat the above procedure for the other valve. Figure 3-11. Valve Spring Compressor (Part No. HD-34736B) Disassemble the other head using the same procedure. 3-14 2002 Buell X1: Engine. Inner Diameter Check end play of rocker arm with feeler gauge. 10. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 2002 Buell X1: Engine 3-15. HD-94804-57). Repeat for other end of rocker arm. 3-16 2002 Buell X1: Engine. HD-39786) NOTE Figure 3-20. Cleaning Valve Guides The hone is not intended to remove material. Figure 3-20. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (1) (Part No. HD-34751) and hot soapy water. 2002 Buell X1: Engine 3-17. Lapping Valves form width around both valve and seat, valve is well seated.Apply LOCTITE THREADLOCKER 271 (red) to threads of new front isolator mount bolts. Figure 3-26. Valve Guide Seal Protector Sleeve 3-20 2002 Buell X1: Engine. Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-27. Mark cylinder head and head screw shoulder with a line as shown (View A).
Tighten screws to 10-14 ft-lbs (14-19 Nm). 17. Install the other cylinder using the same procedure. 3-22 2002 Buell X1: Engine. The pins have tapered ends to help seat the round retaining rings. See Figure 3-32. 1200cc piston pins are stamped with a V-groove at one end. 2002 Buell X1: Engine 3-23. Try to insert a feeler gauge between the straight- edge and the gasket surface.Piston Rings 3-26 2002 Buell X1: Engine. FRONT Piston REAR Figure 3-38. Ring End Gap Position 6614 Figure 3-39. Measuring Ring Clearance in Groove 2002 Buell X1: Engine 3-27. Installing bent connecting rods will damage cylinder and b0700a3x piston beyond repair. Figure 3-41. Piston Pin Bushing Tool Assembly for Bushing Removal 3-28 2002 Buell X1: Engine. Figure 3-44. Compressing Piston Rings 13. Assemble cylinder head. See 3.5 CYLINDER HEAD. 14. Install cylinder head. See 3.5 CYLINDER HEAD. 15. Install assembled engine. See 3.4 INSTALLING THE ENGINE. 2002 Buell X1: Engine 3-29. The colder the weather, the shorter the recommended oil change interval. A vehicle used only for short runs in cold weather must have the engine oil drained frequently. 2002 Buell X1: Engine 3-31. Vent Hose Connection (Typical) Figure 3-45. Oil Tank Hoses 3-32 2002 Buell X1: Engine. Oil Tank loss of control. These events could result in death or serious injury. Install seat. See 2.40 SEAT. 2002 Buell X1: Engine 3-33. Push Rod Cover (2) Oil Drain Hole Umbrella Valve Breather Bolt Figure 3-52. Crankcase Breathing System, Typical Cylinder 2002 Buell X1: Engine 3-35. Cross-drilled pas- through the gear meshing action.Principle of Gerotor Operation 2002 Buell X1: Engine 3-37. Mounting Gasket 11. Gear Shaft 12. Body 13. Return Hose Elbow Connector 14. O-Ring 15. Thrust Washer 16. Retaining Ring Figure 3-55. Oil Pump 3-38 2002 Buell X1: Engine. Add oil to correct level if needed. 1.6 ENGINE LUBRICATION SYSTEM. 2002 Buell X1: Engine 3-39. Thread screw (8) into tapped hole in crankcase. Tighten screw to 15-18 ft-lbs (20-24 Nm).
Install push rods and rocker covers. See 3.5 CYLINDER HEAD. 3-42 2002 Buell X1: Engine. Rear Intake Cam Gear Bushing Front Exhaust Cam Gear 10. Right Crankcase Half 16. Pinion Shaft Bushing Pinion Gear 11. Nut 17. Gearcase Cover Figure 3-62. Gearcase and Valve Train Components 2002 Buell X1: Engine 3-43. Inspect each bushing against its corresponding cam gear shaft or pinion gear shaft. See Table 3-10. Figure 3-65. Use a BUSHING AND BEARING PULLER (Part No. HD-95760-69A) to remove bushings from gearcase cover and crankcase. 3-44 2002 Buell X1: Engine. Using an arbor press, install each ING REAMING (GEARCASE COVER).Orient each 2002 Buell X1: Engine 3-45. Drilling Dowel Pin Hole 3-46 2002 Buell X1: Engine. Blow out all oil passages using com- pressed air.Crankshaft Locking Tool (HD-43984) intake (15-3) cam gears must both be installed before the rear intake (15-2) cam gear is installed. 3-48 2002 Buell X1: Engine. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-74. Checking Cam Gear End Play 2002 Buell X1: Engine 3-49. Crankcase Hardware (Typical) 2002 Buell X1: Engine 3-51. Crankcase Assembly 3-52 2002 Buell X1: Engine. Install Claws on Snap Ring Crankshaft Bearing Tool (Part No HD-9457-101) b0807x3x Figure 3-80. Sprocket Shaft Outer Race Removal Figure 3-82. Remove Snap-Ring From Crankcase Bore 2002 Buell X1: Engine 3-53. Factory Outer Race Sizes 2002 Buell X1: Engine 3-55. HD-95652-43A), and BEARING SEPARA- 1.2499 in. (31.747 mm) OD inner race, a blue bear- TOR (SNAP-ON TOOLS Stock No. CJ950). Apply heat to race to aid removal.HD-96710-40B) 3546a Figure 3-90. Lapping Pinion Shaft Main Bearing 2002 Buell X1: Engine 3-57. HD-42579) to install sprocket shaft tapered roller bearings and seal. 2002 Buell X1: Engine 3-59. HD-45206) onto sprocket shaft. Follow procedure in Step 8. Seal Rotate handle clockwise until the spacer makes contact with the bearing. Remove tool from sprocket shaft.