Buell 2002 X1, Service Manual

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3-8 2002 Buell X1: Engine
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STRIPPING MOTORCYCLE FOR ENGINE REPAIR 3.3
DISASSEMBLING ENGINE FOR
CYLINDER HEAD REPAIR
1. Lift and secure the motorcycle.
a. Place vehicle on a lift and anchor front wheel in
place. Raise lift so the top of the cylinder head is
easy to access.
b. Raise rear wheel off lift using REAR WHEEL SUP-
PORT STAND (Part No. B-41174).
1
WARNING
1
WARNING
To protect agsint shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
1
WARNING
1
WARNING
Always disconnect the negative battery cable first. If the
positive battery cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion which could result in death or seri-
ous injury.
2. Disconnect both battery cables, negative cable first and
remove battery.
1
WARNING
1
WARNING
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (49 psi [338 kPa]). To
avoid an uncontrolled discharge or spray of gasoline,
always purge the system of high pressure gas before
attaching fuel pressure gauge. Gasoline is extremely
flammable and highly explosive. Inadequate safety pre-
cautions could result in death or serious injury.
3. Remove seat and fuel tank. See 4.37 FUEL TANK .
4. Remove air cleaner cover and backplate. See 4.42 AIR
CLEANER .
5. Remove throttle body and manifold. See 4.41 THROT-
TLE BODY AND INTAKE MANIFOLD .
6. Remove support bracket on left side of cylinder heads.
7. Remove exhaust header and muffler. See 2.28
EXHAUST SYSTEM .
8. Disconnect spark plug cables. Remove spark plugs.
9. If removing front cylinder, remove ignition coil ( 4.31 IGNI-
TION COIL ) and horn ( 7.21 HORN ).
NOTE
At this stage, the lower rocker boxes, cylinder heads and cyl-
inders may be removed. See
3.5 CYLINDER HEAD .
ENGINE CRANKCASE
REPLACEMENT OR COMPLETE
ENGINE REMOVAL
1. Perform the steps listed above. In addition, remove bat-
tery from frame.
2. See Figure 3-1. Place a floor hoist behind the lift. Attach
straps to tail section and hoist. Raise hoist until straps
tighten.
3. Detach clutch cable from handlebar lever.
4. Remove rear fender and lower belt guard. See 2.32
REAR FENDER .
5. Remove sprocket cover. See 2.30 SPROCKET COVER .
6. Detach rear brake caliper from caliper mount. See 2.14
REAR BRAKE CALIPER .
7. Detach belt from rear sprocket and remove rear wheel.
See
2.6 REAR WHEEL .
8. Drain oil tank and remove oil filter. See 1.6 ENGINE
LUBRICATION SYSTEM .
9. Detach hoses from oil tank fittings. See 3.9 OIL TANK .
10. Remove both rider footrest mounts from frame. See 2.29
FOOTRESTS .
11. Remove both rear shock mounting bolts (metric).
12. Disconnect wiring. See Section 7.
a. Disconnect neutral switch wire from crankcase.
b. Unplug cam position sensor from wiring harness.
c. Remove solenoid wire, battery positive cable and
circuit breaker charging wire from starter motor.
d. Locate voltage regulator connector near the oil
pump. Disconnect from alternator stator.
e. Detach wire from oil pressure indicator switch. See
3.10 OIL PRESSURE INDICATOR SWITCH .
13. See Figure 3-2. Place a wooden cradle underneath the
crankcase.
Figure 3-1. Floor Hoist
Attach straps
to tail section
7104