Buell 2002 X1, Service Manual

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7-32 2002 Buell X1: Electrical
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INSTALLATION
Headlamp Bulb
1
CAUTION
The bulb contains Halogen gas under pressure. Handle
bulb carefully and wear eye protection. Failure to follow
adequate safety precautions could result in minor or
moderate injury.
CAUTION
Never touch the bulb with your fingers. Fingerprints will
etch the glass and cause the bulb to fail. Always wrap the
bulb in paper or a clean, dry cloth during handling.
1. See Figure 7-37. Install headlamp bulb (6).
a. Align tabs on bulb housing with tabs on headlamp.
Insert bulb.
b. Close the wire retaining latch (1).
c. Connect the headlamp bulb connector.
NOTE
When replacement is required, see your Buell dealer. Not
using the specified bulb may cause charging system problems.
2. Insert position lamp bulb (3).
3. Connect ground wire (5).
4. See Figure 7-36. Place headlamp assembly in housing
(12). Tighten screw (9).
1
WARNING
1
WARNING
Check for proper headlamp operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper headlamp operation could
result in death or serious injury.
5. Check headlamp for proper operation. If operation fails,
reread procedure and verify that all steps were per-
formed.
a. Turn ignition key switch to IGN.
b. See Figure 7-39. Check headlamp LOW (2) and
HIGH beam (1) settings.
c. Set headlamp to LOW beam (2). Press passing
lamp switch (3). Headlamp should flash HIGH beam
for as long as the switch is pressed.
d. Turn ignition key switch to OFF.
6. Align headlamp. See 1.23 HEADLAMP .
Headlamp Housing and Brackets
1. Install headlamp brackets.
a. Install front forks through triple clamps and head-
lamp brackets. See 2.16 FRONT FORK .
b. See Figure 7-36. Install four bolts (3).
c. Attach front turn signals. See 7.13 TURN SIGNALS .
2. See Figure 7-38. Route headlamp wire harness between
front forks and along right side frame tube. Attach con-
nector [38] to wiring harness. Fasten wiring harness to
frame with
new cable straps.
3. See Figure 7-36. Install headlamp housing using two
screws (1) (metric) and washers (2). Tighten screws to
6-8 ft-lbs (8-11 Nm).
1
WARNING
1
WARNING
Check for proper headlamp operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper headlamp operation could
result in death or serious injury.
4. Check headlamp for proper operation. If operation fails,
reread procedure and verify that all steps were per-
formed.
1
WARNING
1
WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
5. Install fuel tank and seat. See 4.37 FUEL TANK.
6. Align headlamp. See 1.23 HEADLAMP .
Figure 7-38. Headlamp Connector [38]
Figure 7-39. Headlamp Controls
O/W
Y
BK
W
POSITION LMP
LMP GROUND
LOW BEAM
HIGH BEAM
1 O/W
4
3
2
Y
BK
W
b0622xa7x
Headlamp
[38]
1. HIGH Beam
2. LOW Beam
3. Passing Lamp Switch
b0773x7x
2
1
3