Buell 2002 X1, Service Manual

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2002 Buell X1: Fuel System 4-93
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INSTALLATION
1. See Figure 4-72. With the lipped side facing inboard,
install new camshaft oil seal (9) into gearcase cover
(10), if removed. Press seal into position until flush with
surface of timer bore.
2. Install trigger rotor (8).
a. Apply LOCTITE THREADLOCKER 243 (blue) to
threads of bolt (6).
b. Position trigger rotor (8) onto end of camshaft align-
ing notch with camshaft slot.
c. Install bolt to secure rotor. Tighten to 43-53 in-lbs
(5-6 Nm).
3. Install cam position sensor (7) and timer plate studs (5).
Rotate cam position sensor to its previously marked
position to obtain approximate ignition timing.
CAUTION
See Figure 4-74. Route sensor wires about 1-1/2 in.
(38 mm) forward of secondary drive belt and sprocket. If
wires are routed too far to the rear of this position, they
could contact the moving secondary drive belt and/or
sprocket resulting in damage to sensor wiring.
4. Route sensor wiring leads.
a. Downward through hole (7 o’clock position) in timer
bore of gearcase cover.
b. Upward through bottom opening between right
crankcase half and rear of gearcase cover.
c. Route wiring in front of tower shaft behind gearcase
cover. Route wires upward to starter motor.
d. Cable strap wiring.
5. See Figure 4-75. Install sensor wiring terminals into cor-
rect positions in plug end of connector [14]. R/W, GN/W
and BK/W wires of plug end (from cam position sensor)
must match same color wires in receptacle end of con-
nector (from ignition module wiring harness). Install pin
terminals. See
7.25 DEUTSCH ELECTRICAL CONNEC-
TORS .
6. See Figure 4-72. Attach connector (17) [14].
7. Check ignition timing. See 1.21 IGNITION TIMING .
8. Tighten timer plate studs (5) to 15-30 in-lbs (2-3 Nm).
9. Install inner cover (4) using screws (3). Tighten to 12-20
in-lbs (1-2 Nm).
CAUTION
Use only H-D Part No. 8699 rivets to secure outer timing
cover. These rivets are specially designed so that no
rivet end falls off into the timing compartment. Use of
regular rivets can damage ignition system components
and may allow water to enter the timing compartment.
10. Secure timer cover (2) to inner cover using new rivets.
1
WARNING
1
WARNING
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
11. Install battery cables, positive cable first.
Figure 4-74. Routing Sensor Wires
Figure 4-75. Connecting Sensor Wires
b0418x7x
8 7 6 5 12 11 10 9 4 3 2 1
/W GN
/W GN
/W BK
/W BK
R/W
R/W
A B C
A B C
A B C
R/W V/Y
BK/W
R/W V/Y
GN/W BK/W
b0765x7x
Throttle
Position
Sensor
[88]
Cam
Position
Sensor
[14]
ECM Connector [11]