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Buell 2002 X1, Service Manual

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Buell 2002 X1 Service Manual Download Page 93

2002 Buell X1: Chassis

2-25

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CAUTION

To  avoid leakage, verify that banjo washers, banjo bolt,
hydraulic brake line and caliper bore are completely
clean.

4.

Connect brake line (1) to caliper using two 

new

  banjo

washers (3) and banjo bolt (2) (metric). Tighten to 16-20
ft-lbs (22-27 Nm).

5.

See 

Figure 2-34.

  Remove both master cylinder cover

screws (2). Remove master cylinder cover (1) plastic
insert and gasket.

6.

With the master cylinder in a level position, verify that the
brake fluid level is 1/8 in. (3.2 mm) from molded boss
inside reservoir. Add 

D.O.T.  4 BRAKE FLUID

  if neces-

sary.

1

1

WARNING

1

WARNING

Verify proper operation of the master cylinder relief port.
A plugged or covered relief port can cause brake drag or
lockup, which may result in loss of vehicle control. These
events could result in death or serious injury. 

7.

Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
components are working properly.

8.

See 

Figure 2-34.

  Install master cylinder cover, plastic

insert and gasket with two screws. Tighten to 9-13 

in-lbs

(1-2 Nm).

1

1

WARNING

1

WARNING

Always test motorcycle brakes at low speed after servic-
ing or bleeding system. To prevent death or serious
injury, Buell recommends that all brake repairs be per-
formed by a Buell dealer or other qualified mechanic.

9.

Depress front brake lever several times to set brake pads
to proper operating position within caliper. Bleed brake
system. See 

1.7 BRAKES

.

10. Check clearance between front caliper mounting bolts

and T-40 TORX screws on rotor. See 

1.7 BRAKES

.

1

1

WARNING

1

WARNING

Check for proper brake lamp operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper brake lamp operation could
result in death or serious injury.

11. Turn ignition key switch to IGN. Apply brake hand lever to

test brake lamp operation. Turn ignition key switch to
LOCK.

NOTE

Avoid making hard stops for the first 100 miles (160 km) to
allow 

new

  brake pads to “wear in” properly with the brake

rotor.

Figure 2-33. Installing Brake Pads

Figure 2-34. Master Cylinder Cover (Typical)

Figure 2-35. Front Master Cylinder Gasket 

7084

This surface 
against brake rotor

7047

1.

Master Cylinder Cover

2.

Screws (2)

1

2

2

7089

Summary of Contents for 2002 X1

Page 1: ...02 BUELL X1 SERVICE MANUAL Part Number 99490 02Y Section 1 Maintenance Section 2 Chassis Section 3 Engine Section 4 Fuel System Section 5 Starter Section 6 Drive Transmission Section 7 Electrical Appendix ...

Page 2: ...1 2 2002 Buell X1 Engine Printed July 25 2001 11 21 am ...

Page 3: ...ear Wheel Support Stand and Part No B 41174 2 Replacement Pad Part No B 41177 Front Fork Holding Tool Part No B 41325 99 Scanalyzer Software Cartridge Part No B 42887 Brake Caliper Piston Remover Part No B 43721 Front Fork Seal Driver Part No B 43875 Fork Spring Compressor Part No B 45110 Shock Preload Adjustment Tools ...

Page 4: ...evel Oil Gauge Part No HD 01289 Rim Protectors Part No HD 21000 Tire Spreader Part No HD 23738 Vacuum Pump Part No HD 25070 Robinair Heat Gun Part No HD 26792 Spark Plug Tester Part No HD 28700 Tire Bead Expander Part No HD 33067 Wheel Bearing Packer ...

Page 5: ... 33418 Universal Puller Forcing Screw Part No HD 33446A Cylinder Torque Plates and Torque Plate Bolts Part No HD 33446 86 Part No HD 34623B Piston Pin Retaining Ring Installer Remover Part No HD 34643A Shoulderless Valve Guide Seal Installer Part No HD 34723 Valve Guide Hone 8 mm Part No HD 34730 2C Fuel Injector Test Lamp ...

Page 6: ... HD 34740 Driver Handle and Remover Used with HD 34643A and HD 34731 Part No HD 34751 Nylon Valve Guide Brush Part No HD 34813 Rowe Flywheel Rebuilding Jig Part No HD 34816 Oil Pressure Switch Wrench Part No HD 35102 Wrist Pin Bushing Hone 20 mm Part No HD 35316 A Main Drive Gear Remover Installer and Main Drive Gear Bearing Installer ...

Page 7: ...dpob npond bndb n CYLINDER LEAKDOWN TESTER Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pffb odlbndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho knsdl hlno hslnslp pffb odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pklhb odlb...

Page 8: ...nnectors Part No HD 38125 7 Packard Terminal Crimp Tool Sealed connectors Part No HD 38125 8 Packard Terminal Crimp Tool Part No HD 38361 Cam Gear Gauge Pin Set 0 108 in 2 74 mm Diameter Part No HD 38362 Sprocket Locking Link Part No HD 38515 A Clutch Spring Compressing Tool and Part No HD 38515 91 Forcing Screw Part No HD 38871 Camshaft Bushing Plate Pilot and Reamer ...

Page 9: ...er Part No HD 39302 Steering Head Bearing Race Installer Part No HD 39458 Sprocket Shaft Bearing Outer Race Installer T S P O R S TE R 1 3 C C 4 0 Part No HD 39565 Engine Sound Probe Part No HD 39617 Inductive Amp Probe Use with HD 35500A Part No HD 39621 Electrical Terminal Repair Kit Part No HD 39621 27 Socket Terminal Remover ...

Page 10: ... No HD 39786 Cylinder Head Holding Fixture Part No HD 39800 Oil Filter Crusher Small Part No HD 39823 Oil Filter Crusher Large Part No HD 39847 Universal Ratcheting Tap Reamer Handle Part No HD 39932 Steel or HD 39932 CAR Carbide Intake and Exhaust Valve Guide Reamer Part No HD 39964 Reamer Lubricant Cool Tool ...

Page 11: ...art No HD 39978 Fluke 78 Multimeter DVOM Part No HD 39994 Paint Repair Kit Part No HD 41025 Tool Organizational System Part No HD 41137 Hose Clamp Pliers Part No HD 41155 VHS Video Shelf Part No HD 41182 Fuel Pressure Gauge 10 0 150 200 25 0 30 0 350 400 450 500 55 0 600 650 250 100 10 20 30 40 50 60 70 80 90 ...

Page 12: ...Part No HD 25070 Part No HD 41185 Hose Cutting Tool Part No HD 41185 1 Oil Hose Cutter Part No HD 41321 Sprocket Holding Tool Part No HD 41325 Scanalyzer Part No HD 41404 Test Connector Kit Part No HD 41496 Main Drive Gear Seal Installer Part No HD 41506 Crankshaft Locking Tool ...

Page 13: ... Wrench Part No HD 42310 Engine Transmission Stand Part No B 42310 150 Drip Pan Used with Part No HD 42310 Part No HD 42311 Oil Filter Wrench Part No HD 42320 Piston Pin Remover Installer Part No HD 42322 Piston Support Plate Part No HD 42376 Battery Charging System Load Tester 600 200 Made in USA PP 9606 0001 ...

Page 14: ...Breakout Box Part No HD 43646 Engine Stand Part No HD 44069 Timkin Snap Ring Remover Installer Part No HD 43984 Crankshaft Locking Tool Part No HD 44069 Timkin Snap Ring Remover Installer Part No HD 44358 Flywheel Fixture 2000 Models Part No HD 44404 Sprocket Shaft Inner Timkin Bearing Remover ...

Page 15: ...Part No HD 94547 102 Drive Handle Used with HD 94547 100 and HD 94547 101 Part No HD 94660 37B Mainshaft Locknut Wrench Part No HD 94800 26A Connecting Rod Bushing Reamers and Pilots Part No HD 94803 67 Rear Intake Camshaft Bushing Reamer Part No HD 94804 57 Rocker Arm Bushing Reamer Part No HD 94812 1 Pinion Shaft Bushing Reamer Use with HD 94812 87 ...

Page 16: ...e Claw Puller Part No HD 95637 46A Wedge Attachment for Claw Puller Use with HD 95635 46 Part No HD 95760 69A Bushing Bearing Puller Tool Set Set includes items 1 7 Items 8 HD 95769 69 9 HD 95770 69 and 10 HD 95771 69 are optional Part No HD 95952 33B Connecting Rod Clamping Tool Part No HD 95970 32D Piston Pin Bushing Tool Part No HD 96215 49 Small Internal Retaining Ring Pliers ...

Page 17: ... Piston Ring Compressor Part No HD 96550 36A Valve Lapping Tool Part No HD 96650 80 Flywheel Truing Stand Part No HD 96710 40B Crankcase Main Bearing Lapping Tool Part No HD 96718 87 Pinion Bearing Outer Race Lapping Kit Part No HD 96740 36 Connecting Rod Lapping Arbor Part No HD 96796 47 Valve Spring Tester ...

Page 18: ...e Gauge Part No HD 96940 52A Oil Pressure Gauge Adapter Use with HD 96921 52A Part No HD 97087 65B Hose Clamp Pliers Part No HD 97292 61 Two Claw Puller Part No HD 99500 80 Wheel Truing and Balancing Stand Part No J 5586 Transmission Shaft Retaining Ring Pliers ...

Page 19: ... 488 4 527 4 567 4 606 4 645 4 685 4 724 4 764 4 803 4 842 001 002 003 004 005 006 007 008 009 010 1 64 020 030 1 32 040 050 060 1 16 070 080 090 1 1 8 3 16 2 1 4 3 5 16 3 8 4 7 16 1 2 9 16 025 051 076 102 127 152 178 203 229 254 397 508 762 794 1 016 1 270 1 524 1 588 1 778 2 032 2 286 2 540 3 175 4 762 5 080 6 350 7 620 7 938 9 525 10 160 11 112 12 700 14 288 6 5 8 11 16 7 3 4 8 13 16 7 8 9 15 1...

Page 20: ...EEL 120 000 PSI MEDIUM CARBON HEAT TREAT 14 22 10 19 33 54 78 114 154 257 382 587 SAE 7 STEEL 133 000 PSI MEDIUM CARBON ALLOY 13 25 44 71 110 154 215 360 570 840 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SOCKET SET SCREW 212 000 PSI HIGH CARBON QUENCHED TEMPERED 9 16 30 70 140 18 2...

Page 21: ...21 1 10 Clutch 1 22 1 11 Drive Belt Deflection 1 24 1 12 Drive Belt and Sprocket 1 26 1 13 Primary Chain 1 28 1 14 Preload Adjustment 1 29 1 15 Suspension Damping Adjustments 1 30 1 16 Front Fork 1 31 1 17 Steering Head Bearings 1 32 1 18 Spark Plugs 1 34 1 19 Air Cleaner Filter 1 35 1 20 Throttle Cables 1 36 1 21 Ignition Timing 1 37 1 22 Handlebars 1 39 1 23 Headlamp 1 40 1 24 Storage 1 41 1 25 ...

Page 22: ......

Page 23: ...nd in the appropriate PARTS CATALOG Safety Safety is always the most important consideration when per forming any job Be sure you have a complete understanding of the task to be performed Use common sense Use the proper tools Protect yourself and bystanders with approved eye protection Don t just do the job do the job safely Removing Parts Always consider the weight of a part when lifting Use a ho...

Page 24: ...hat makes direct contact with the mating part Always use the proper tools and fixtures for removing and installing bearings Bearings do not usually need to be removed Only remove bearings if necessary Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with...

Page 25: ...ye protection Wrenches Never use an extension on a wrench handle If possible always pull on a wrench handle and adjust your stance to prevent a fall if something lets go Never cock a wrench Never use a hammer on any wrench other than a STRIK ING FACE wrench Discard any wrench with broken or battered points Never use a pipe wrench to bend raise or lift a pipe Pliers Cutters Prybars Plastic or vinyl...

Page 26: ... of pressure as a test to be sure the ratchet s gear wheel is engaged with the pawl Sockets Never use hand sockets on power or impact wrenches Select the right size socket for the job Never cock any wrench or socket Select only impact sockets for use with air or electric impact wrenches Replace sockets showing cracks or wear Keep sockets clean Always use approved eye protection when using power or...

Page 27: ...llowed If large amount of fluid is swallowed induce vomiting by administering two tablespoons of salt in a glass of warm water Call a doc tor In case of contact with skin or eyes flush with plenty of water Get medical attention for eyes KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Failure to comply could result in death or serious injury Use only D O T 4 BRAKE FLUID Part No 99953 99Y FUEL Use a g...

Page 28: ...upright not on side stand on a level surface Oil level Between upper and lower marks on dipstick Oil tank capacity with filter change 2 5 quarts 2 37 liters Oil filter 1 6 ENGINE LUBRICATION SYSTEM R R R R R R R R Hand tighten filter 1 2 3 4 turn after gasket contacts surface Brake fluid level and condition 1 7 BRAKES I I I I I I I I I I I I I I I I Fluid type D O T 4 BRAKE FLUID Part No HD 99953 ...

Page 29: ...ENSION GAUGE Part No HD 35381 I A I I I I I I Belt deflection with 10 lbs 4 5 kg of upward force suspension unloaded 1 50 1 75 in 38 1 44 5 mm Rear axle nut torque 68 73 ft lbs 89 5 98 9 Nm Primary chain 1 13 PRIMARY CHAIN I I I I I I I Chain freeplay with hot engine 1 4 3 8 in 6 4 9 5 mm Chain freeplay with cold engine 3 8 1 2 in 9 5 12 7 mm Inspection screws torque 40 60 in lbs 4 5 6 8 Nm Rear s...

Page 30: ...r Section 2 L L L L L L L Check for damage and freeplay Operation of throttle controls 1 20 THROTTLE CABLES I I I I I I I I I I I I I I Controls must be smooth and not binding Engine idle speed 1 21 IGNITION TIMING I I I I I I I I I I I I I I Regular idle 850 1050 RPM Ignition timing 1 21 IGNITION TIMING HARNESS CONNECTOR TEST KIT Part No HD 41404 I I I I I I Fuel supply hoses and fittings for lea...

Page 31: ...de stand 2 41 SIDE STAND I L L L L L L Engine mounts Section 3 I I I I I I I Starter Interlock system 7 5 STARTER INTERLOCK I I I I I I I I I I I I I Operation of all electrical equipment and switches Section 7 I I I I I I I I I I I I I I I All fasteners except engine head bolts T T T T T T T Road test X X X X X X X X X X X X X X SERVICE OPERATIONS AND SPECIAL TOOLS P R E R I D E 5 0 0 MI 8 0 0 K ...

Page 32: ...1 10 2002 Buell X1 Maintenance HOME NOTES ...

Page 33: ...dry natural fiber cloth Cleaning Between Washings Untreated molded in color body panels sometimes have a static charge that attracts dust Applying Harley Gloss or Har ley Glaze Polish and Sealant to molded in color surfaces will eliminate this condition To keep a high gloss finish on molded in color panels between washings follow the instructions below Spray Harley Gloss onto surface and wipe with...

Page 34: ...ducts and techniques outlined in these instructions to avoid damage RECOMMENDED PRODUCT The blue ceramic header surface has a matted surface and should not be buffed The product recommended for the proper care and maintenance is listed below and are avail able at your Buell dealer Harley Sunwash Part No 94659 98 CARE AND MAINTENANCE Washing To wash blue ceramic header follow the instructions below...

Page 35: ...terminal 3 Unthread bolt and remove battery positive cable red from battery positive terminal 4 Remove battery strap locknut metric Unhook battery strap from frame near negative terminal 5 Cut any cable straps holding oxygen sensor connector to battery 6 Remove battery from right side CLEANING AND INSPECTION 1 Battery top must be clean and dry Dirt and electrolyte on top of the battery can cause b...

Page 36: ...oil ing When returning a battery to service after storage fully charge the battery See 7 10 BATTERY BATTERY INSTALLATION AND CONNECTION 1 Place the fully charged battery into the battery box ter minal side forward CAUTION Connect the cables to the correct battery terminals or damage to the motorcycle electrical system will occur 11WARNING 1WARNING Always connect the positive battery cable first If...

Page 37: ...ommended viscosity depends upon ambient temperature See Table 1 4 If it is neces sary to add oil and Harley Davidson oil is not avail able use an oil certified for diesel engines Acceptable diesel engine oil designations include CE CF CF 4 and CG 4 The preferred viscosities for the diesel engine oils in descending order are 20W 50 15W 40 and 10W 40 At the first opportu nity see a Buell dealer to c...

Page 38: ... crank case surface Apply another 1 2 3 4 turn by hand 9 Remove seat See 2 40 SEAT 11WARNING 1WARNING Be sure no oil gets on tires when changing oil and filter Traction will be adversely affected which may lead to loss of control which could result in death or serious injury 10 Fill oil tank with an oil from Table 1 4 Oil tank capacity is 2 5 quarts 2 37 liters including the 4 0 ounces 0 12 liter ...

Page 39: ...et medical attention for eyes KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Failure to comply could result in death or serious injury 11WARNING 1WARNING Never mix D O T 4 with other brake fluids such as D O T 5 Use only D O T 4 brake fluid in motorcycles that spec ify D O T 4 fluid on the reservoir cap Mixing different types of fluid may adversely affect braking ability and lead to brake failure w...

Page 40: ...ase and then hold brake lever pedal to build up hydraulic pressure 4 Open bleeder valve about 1 2 turn counterclockwise brake fluid will flow from bleeder valve and through tub ing When brake lever pedal has moved 1 2 to 3 4 of its full range of travel close bleeder valve clockwise Allow brake lever pedal to return slowly to its released position 5 Repeat Steps 2 4 until all air bubbles are purged...

Page 41: ...tely 0 84 in 21 3 mm slide rubber boot 1 down over assembly Brake pedal adjustment is not needed b If measurement is not within specification adjust brake pedal NOTE See Figure 1 13 Minimum allowable pushrod thread engage ment inside turn buckle is 0 24 in 6 0 mm 3 Adjust brake pedal a See Figure 1 12 Loosen locknut 3 while holding rod adjuster Move locknut away from top surface of turn buckle b T...

Page 42: ... brake pads using procedure under 2 14 REAR BRAKE CALIPER BRAKE ROTORS Brake Rotor Thickness 11WARNING 1WARNING Do not allow brake fluid bearing grease lubricants etc to contact brake rotor when servicing motorcycle or reduced braking ability will occur which could result in death or serious injury Check brake rotors for minimum thickness At the 500 mile 800 km service interval At every scheduled ...

Page 43: ... WHEEL BEARINGS 11WARNING 1WARNING Never use compressed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bearings with compressed air can also cause a bearing to fly apart which could result in death or seri ous injury Check wheel bearings Every time the wheel is removed At every 10 000 mile 16 000 km service interval When storing or removing the motorcyc...

Page 44: ...n to 14 30 ft lbs 19 41 Nm 5 Remove four TORX screws with washers from clutch inspection cover Remove clutch inspection cover from primary cover Do not damage or dislodge Quad ring from primary cover CAUTION Do not overfill the transmission with fluid Overfilling may cause rough clutch engagement and incomplete disengagement clutch drag and or difficulty finding neu tral at engine idle 6 See Figur...

Page 45: ...justing screw 6 clockwise 1 4 turn Install lock plate 5 and spring 4 on adjusting screw flats If hex on lockplate does not align with recess in outer ramp rotate adjusting screw clockwise until it aligns 6 Squeeze clutch hand lever to maximum limit three times This sets the ball and ramp mechanism Pull outer cable conduit and at the same time adjust cable adjuster to provide 1 16 1 8 in 1 6 3 2 mm...

Page 46: ...torcycle s weight is not compressing the rear shock It is not necessary to raise the rear wheel off the ground to reach this point 4 See Figure 1 21 Apply 10 lbs of force using BELT TEN SION GAUGE Part No HD 35381 at the midpoint of the belt s bottom strand The deflection should be upward as shown a Deflection measured with 10 lbs of force should be 1 50 1 75 in 38 45 mm at the bottom strand If de...

Page 47: ...ion rear wheel alignment loosen locknut 2 hold axle adjuster bolt 1 and turn adjusting nut 3 a If belt is too loose tighten adjusting nut 3 to decrease deflection and therefore increase drive belt tension b If belt is too tight loosen adjusting nut 3 to increase belt deflection and therefore decrease drive belt tension c See Figure 1 23 Repeat this step until the distance between the flat on the a...

Page 48: ...g the bare aluminum A knife point will not penetrate the chrome plating 3 Replace rear sprocket if major tooth damage or loss of chrome exists Drive Belt See Figure 1 25 Inspect drive belt for Cuts or unusual wear patterns Outside edge bevelling 8 Some bevelling is common but it indicates that sprockets are misaligned Outside ribbed surface for signs of stone puncture 7 If cracks damage exists nea...

Page 49: ...t monitor condition 2 External tooth cracks Replace belt 3 Missing teeth Replace belt 4 Chipping not serious OK to run but monitor condition 5 Fuzzy edge cord OK to run but monitor condition 6 Hook wear Replace belt 7 Stone damage Replace belt if damage is on the edge 8 Bevel wear outboard edge only OK to run but monitor condition 1 2 3 4 5 6 7 8 Stone Cross Section View b0594x1x Sprocket Side of ...

Page 50: ...n the drive as measured with special ized factory equipment If a chain has less than 1 4 in 6 4 mm vertical free play with a cold engine adjust free play to the field specification of 3 8 1 2 in 9 5 12 7 mm The looser specification will avoid overtightening which might oth erwise occur during adjustment using non factory equip ment and methods 5 See Figure 1 26 Install O ring 4 6 Fasten inspection...

Page 51: ...he can towards the rear of the motorcy cle NOTE All measurements must be taken with rider seated on motorcycle Riders with passenger at or near GVWR may exceed optimum shock length measurement preload adjust ment 3 See Figure 31 When preload adjustments have been made apply wheel bearing grease halfway around the shock 180 degrees to the mating faces of the locknut and adjuster nut and the first f...

Page 52: ...1 Using a screwdriver turn the slotted dial on the appropriate adjuster clockwise until it stops This is the maximum damping setting for that adjustment 2 Then turn the dial counterclockwise the recommended amount to align the reference marks This is the factory recommended setting Rear Shock Rebound Damping See lower frame of Figure 1 33 Adjust rebound damping using the slotted dial on the remote...

Page 53: ...amount of recommended fork oil into fork pipe 6 Check fork oil level Maximum and minimum oil levels are listed in Table 1 8 a With front fork fully compressed clamp vertically in FRONT FORK HOLDING TOOL Part No B 41177 b Measure distance from fork oil 4 surface to top of outer tube 1 using PRO LEVEL OIL GAUGE Part No B 59000A See Figure 1 35 c Add or drain fork oil as needed until distance from to...

Page 54: ...e is extremely flammable and highly explosive Inadequate safety pre cautions could result in death or serious injury 3 Purge fuel line and remove fuel tank See 4 37 FUEL TANK 4 See Figure 1 37 Attach lifting straps to frame tubes behind steering neck Raise front wheel off floor using a floor hoist and lifting straps 5 Turn front wheel to full right lock 6 See Figure 1 38 Hook a spring scale into t...

Page 55: ... or loosen fork stem bolt 1 to set proper tension 5 Recheck tension using spring scale 6 Tighten both lower triple clamp pinch screws 7 to 18 20 ft lbs 24 27 Nm 7 Tighten small pinch screw 8 on upper triple clamp to 10 12 ft lbs 14 16 Nm Figure 1 39 Steering Head Assembly b0373x2x 2 8 1 3 5 4 4 5 3 6 7 9 1 Fork Stem Bolt 2 Upper Triple Clamp 3 Dust Shield 2 4 Roller Bearing 2 5 Bearing Cup 2 6 Low...

Page 56: ... running engine valves not seating or improper ignition timing The glassy deposit on the spark plug is a conductor when hot and may cause high speed misfiring A plug with eroded electrodes heavy deposits or a cracked insulator must be replaced d A plug with a white yellow tan or rusty brown pow dery deposit indicates balanced combustion Clean off spark plug deposits at regular intervals 5 If the p...

Page 57: ...take system fire which could result in death or serious injury 1 Check filter element Hold filter element up to strong light source The element can be considered sufficiently clean if light is uniformly visible through the element 2 Thoroughly clean backplate filter box and inside of cover INSTALLATION 1 See Figure 1 43 Place filter element 1 inside back plate Align tabs 4 on element with tabs on ...

Page 58: ...1 45 Turn adjuster on throttle control cable until throttle cam stop 5 touches stop plate Tighten jam nut on throttle control cable adjuster release throttle control grip 7 Turn handlebars fully to right Turn adjuster on idle con trol cable 3 until end of cable housing just touches the cable guide 2 8 See Figure 1 44 Twist and release throttle control grip a few times Throttle plate must return to...

Page 59: ...transmission into fifth gear NOTE If valves are not visible through spark plug hole in Step 4a place finger over spark plug hole opening The moment air is no longer escaping through spark plug hole the intake valve has closed 4 Bring engine to top dead center TDC a Standing on left side of vehicle slowly rotate rear wheel in a counter clockwise direction until front intake valve opens and closes a...

Page 60: ...d remove jack 9 Remove BREAKOUT BOX harness and connect elec tronic control module connector 11 11WARNING 1WARNING 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 10 Install seat See 2 40 SEAT Figure 1 48 Static ...

Page 61: ...screws and rubber washers 2 See Figure 1 50 Detach instrument support by removing both instrument support screws 3 3 Loosen clamp screws 1 2 4 Move handlebar to desired position 5 Tighten clamp screws to 10 12 ft lbs 14 16 Nm NOTE First tighten the front clamp screws 1 to 10 12 ft lbs 14 16 Nm Once the front clamp screws are tight tighten the rear clamp screws to 10 12 ft lbs 14 16 Nm 6 Install in...

Page 62: ... Stand motorcycle upright with both tires resting on floor and with front wheel held in straight alignment directly forward 7 See Figure 1 52 Turn ignition switch to IGN Set handle bar headlamp switch to HIGH beam position 1 8 Check light beam for alignment a The main beam which is a broad flat pattern of light should be centered equally above and below the horizontal line b The main beam of light...

Page 63: ...IVE BELT DEFLECTION 6 Adjust primary chain See 1 13 PRIMARY CHAIN 7 Check tire inflation See 1 9 TIRES AND WHEELS If the motorcycle will be stored for an extended period of time securely support the motorcycle under the frame so that all weight is off the tires 11WARNING 1WARNING Do not apply any oil to brake rotors or brake pads Oil on brake pads degrades braking efficiency and can result in an a...

Page 64: ... idle screw not set properly See dealer 21 No output from CMP sensor See dealer 22 Inoperative fuel pump See dealer Starts Hard 1 Spark plugs in bad condition have improper gap or are partially fouled 2 Spark plug cables in bad condition and shorting 3 Battery nearly discharged 4 Loose wire connection at one of the battery terminals at coil or at plug between ignition sensor and module 5 Throttle ...

Page 65: ... Uses Too Much Oil or Smokes Excessively 1 Piston rings badly worn or broken 2 Valve stem seals worn or damaged 3 Valve guides worn Engine Leaks Oil From Cases Push Rods Hoses 1 Loose parts 2 Imperfect seal at gaskets push rod cover washers etc To aid locating leaks use BLACK LIGHT LEAK DETEC TOR Part No HD 35457 3 Restricted oil return line to tank 4 Restricted breather passage s to air cleaner E...

Page 66: ...ly inflated See 1 9 TIRES AND WHEELS Do not overinflate 2 Loose wheel axle nuts metric Tighten front nut to 48 53 ft lbs 65 72 Nm Tighten rear nut to 66 73 ft lbs 90 99 Nm 3 Excessive wheel hub bearing play 4 Rear wheel out of alignment with frame and front wheel 5 Rims and tires out of true sideways tire runout should not be more than 0 080 in 2 03 mm 6 Rims and tires out of round or eccentric wi...

Page 67: ...ront Fork 2 37 2 17 Fork Stem and Bracket Assembly 2 42 2 18 Steering Head Lock 2 44 2 19 Swingarm 2 45 2 20 Rear Isolators 2 50 2 21 Rear Shock Absorber 2 53 2 22 Suspension Theory 2 55 2 23 Suspension Adjustments 2 56 2 24 Throttle Control 2 59 2 25 Clutch Control 2 61 2 26 Instrument Support 2 63 2 27 Handlebars 2 64 2 28 Exhaust System 2 65 2 29 Footrests 2 69 2 30 Sprocket Cover 2 70 2 31 Fro...

Page 68: ......

Page 69: ...lop Sportmax Radial II 170 60 ZR 17 D207 36 PSI 248 kPa 38 PSI 262 kPa ITEM TORQUE NOTES Battery Strap Nut 40 in lbs 4 5 Nm page 2 36 Battery Terminal Fastener 60 96 in lbs 7 11 Nm page 2 36 Brake Caliper Banjo Bolt 16 20 ft lbs 22 27 Nm metric page 2 25 Brake Caliper Bleeder Valve 3 5 ft lbs 4 7 Nm metric page 2 24 Brake Hand Lever Nut 44 62 in lbs 5 7 Nm metric page 2 21 Brake Hand Lever Pivot B...

Page 70: ...NTI SEIZE page 2 41 Front Master Cylinder Banjo Bolt 16 20 ft lbs 22 27 Nm metric page 2 22 Front Master Cylinder Cover Screws 9 13 in lbs 1 0 1 5 Nm page 2 22 Fuel Tank Bracket Screws 9 11 ft lbs 12 15 Nm page 2 75 Handlebar Clamp Screws 10 12 ft lbs 14 16 Nm tighten front screws first page 2 64 Handlebar Control Housing Screws Left Side 25 33 in lbs 3 4 Nm metric page 2 62 Handlebar Control Hous...

Page 71: ...ic page 2 29 Rear Master Cylinder Mounting Screws 8 10 ft lbs 11 14 Nm LOCTITE THREADLOCKER 243 blue metric page 2 29 Rear Shock Front Allen Screw 40 45 ft lbs 54 61 Nm page 2 53 Rear Shock Rear Bolt 30 33 ft lbs 41 45 Nm metric page 2 48 Seat Lock Nuts 20 25 in lbs 2 3 Nm page 2 80 Shift Lever Bolt 27 29 ft lbs 37 39 Nm page 2 74 Side Plate Mounting Screws 16 19 ft lbs 22 26 Nm page 2 51 Sprocket...

Page 72: ...idth of the bead seat measured in inches 17 0 is the normal diameter of the rim in inches mea sured at the bead seat diameter DOT means that the rim meets Department of Transpor tation Federal Motor Vehicle Safety Standards See the tables below Figure 2 1 Rim Markings Markings 7040 Table 2 1 Tire Fitment Tubeless Cast Wheels WHEEL SIZE POSITION CONTOUR RIM SIZE RIM VALVE HOLE DIAMETER DUNLOP SPORT...

Page 73: ...breviated V I N when ordering parts or making inquiries about your Buell motorcycle Figure 2 3 Vehicle Identification Number V I N Figure 2 2 Abbreviated V I N Location b0304x2x 4 MZ SS 11 J 2 3 200001 Varies can be 0 9 or X Sample V I N as it appears on the steering head 4MZSS11J123200001 Sample abbreviated V I N as it appears on the left side crankcase SS112200001 11 World 56 California Manufact...

Page 74: ...3 ft lbs 65 72 Nm Tighten rear axle nut metric to 66 73 ft lbs 90 99 Nm Excessive side play or radial up and down play in wheel hubs Replace wheel hub bearings Alignment of rear wheel in frame or with front wheel Check Axle Alignment under 1 11 DRIVE BELT DEFLECTION or repair swingarm as described under 2 19 SWINGARM Rims and tires out of true sideways should not be more than 0 080 in 2 03 mm Repl...

Page 75: ...me cases small punctures in the tread area may be repaired from within the demounted tire by your Buell dealer Speed should not exceed 50 mph 80 km h for the first 24 hours after repair and the repaired tire should NEVER be used over 80 mph 1340 km h In emergency situations if a temporary repair is made ride slowly with as light of a load as possible until the tire is permanently repaired or repla...

Page 76: ...bearings 4 9 using BUSHING AND BEARING PULLER Part No HD 95760 69A and 3 4 in COLLET Part No HD 95767 69A 3 See Figure 2 5 Remove five T 40 TORX screws 12 to detach front brake rotor 13 from wheel hub Discard T 40 TORX screws 4 Remove tire See 2 8 TIRES CLEANING AND INSPECTION 11WARNING 1WARNING Never use compressed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings...

Page 77: ...WARNING 1WARNING Do not allow brake fluid bearing grease lubricants etc to contact brake rotor or reduced braking ability will occur which could result in death or serious injury 8 See Figure 2 6 Install front brake rotor 13 on right side of wheel Slots in carrier must line up with wheel spokes a Verify that the front brake carrier is thoroughly clean b Apply LOCTITE THREADLOCKER 243 blue to threa...

Page 78: ...h axle through spacer and left fork leg 2 Compress the front suspension to make sure it is free and not binding 3 Install axle nut 4 a Apply LOCTITE THREADLOCKER 243 blue to axle threads b Install washer 3 and axle nut 4 metric over threaded end of axle c See Figure 2 5 Insert screwdriver or steel rod through hole 1 in axle d While holding axle stationary tighten axle nut 4 metric to 48 53 ft lbs ...

Page 79: ...condary drive belt from bottom of belt sprocket and remove 6 Remove rear axle nut 1 metric lockwasher 2 washer 3 and axle carrier 4 7 See Figure 2 9 Pull axle 3 and washer 4 out from left side and remove wheel Support caliper mount from frame Figure 2 8 Rear Wheel Mounting Right Side 6851 1 4 6 1 Axle Nut metric 2 Lockwasher 3 Washer 4 Axle Carrier 5 Axle Adjuster Bolt 6 Locknut 7 Locknut 7 2 3 5 ...

Page 80: ...n death or serious injury 1 See Figure 2 9 Install rear brake rotor 2 on side of wheel hub with room for a single wheel bearing Place rotor surface listing minimum thickness specification away from wheel hub a Verify that rear brake rotor is thoroughly clean b Apply LOCTITE THREADLOCKER 272 red to each of the four screws 1 metric c Fasten rotor to wheel hub using screws Tighten to 35 40 ft lbs 48 ...

Page 81: ... wheel hub and right side of swingarm 6 Slide axle 1 through spacer swingarm and axle carrier 5 d Place washer 4 on axle with rounded side facing swingarm Install lockwasher 3 and axle nut 2 metric Do not fully tighten rear axle nut at this time 3 Attach rear brake caliper to caliper mount See 2 14 REAR BRAKE CALIPER 4 Check for proper belt tension and wheel alignment See 1 11 DRIVE BELT DEFLECTIO...

Page 82: ... 2 4 Rim Radial Runout 1 See Figure 2 14 Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification shown in Table 2 4 Table 2 4 Wheel Runout WHEEL TYPE MAXIMUM LATERAL RUNOUT MAXIMUM RADIAL RUNOUT Cast 0 040 in 1 02 mm 0 ...

Page 83: ... Loosen both tire beads from rim flange 11WARNING 1WARNING Do not use excessive force when starting bead over rim Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury 4 If a bead breaker machine is not available attach RIM PROTECTORS Part No HD 01289 to the rim Using tire tools not sharp instruments start upper bead over edge of rim at ...

Page 84: ...ith tire tools working toward valve in both directions 11WARNING 1WARNING Do not inflate over 40 psi 275 kPa to seat the beads Inflating the tire beyond 40 psi 275 kPa to seat the beads can cause the tire rim assembly to burst with force sufficient to cause death or serious injury If the beads fail to seat to 40 psi 275 kPa deflate and relubricate the bead and rim and reinflate to seat the beads b...

Page 85: ...alance is 1 0 oz 28 g total weight applied to the front wheel 2 0 oz 56 g total weight applied to the rear wheel Wheels should be balanced to within 1 4 oz 7 g at 60 MPH 97 KM H See Figure 2 20 Use only WHEEL WEIGHTS Part No 43692 94Y which have special self adhesive backings Apply WHEEL WEIGHTS to the flat surface of the wheel rim 1 Make sure that area of application is completely clean dry and f...

Page 86: ...nd skin and may be harmful if swallowed If large amount of fluid is swallowed induce vomiting by administering two tablespoons of salt in a glass of warm water Call a doc tor In case of contact with skin or eyes flush with plenty of water Get medical attention for eyes KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Failure to comply could result in death or serious injury 11WARNING 1WARNING Never m...

Page 87: ...n pads Loose mounting bolts Warped rotor Replace brake pads Tighten bolts Replace rotor Ineffective brake lever pedal travels to limit Low fluid level Piston cup not functioning Fill master cylinder with approved brake fluid and bleed system Rebuild cylinder Ineffective brake lever pedal travel normal Distorted or glazed rotor Distorted glazed or contaminated brake pads Replace rotor Replace pads ...

Page 88: ...shers 4 Remove screw 8 or unplug both terminals to detach brake lamp switch 7 NOTE The individual parts of the brake lamp switch are not service able Replace switch upon failure 5 Remove two screws 1 metric and clamp 2 to detach master cylinder assembly from handlebar DISASSEMBLY 1 See Figure 2 23 Detach front brake hand lever a Remove nut 1 metric from lever pivot b Remove pivot bolt 2 from lever...

Page 89: ...if any scratches dents or other damage is noted 5 Inspect boot for cuts tears or general deterioration Replace as necessary ASSEMBLY 1 See Figure 2 25 Check piston assembly components a Small end of spring 1 sits behind primary cup 2 Large side of primary cup faces spring b Secondary cup 3 sits within ridge at middle of pis ton 4 2 Insert piston assembly spring first into master cylinder Secure wi...

Page 90: ...der reservoir 11WARNING 1WARNING Verify proper operation of the master cylinder relief port A plugged or covered relief port can cause brake drag or lockup which could result in loss of vehicle control which could result in death or serious injury 7 Verify proper operation of the master cylinder relief port Actuate the brake lever with the reservoir cover removed A slight spurt of fluid will break...

Page 91: ...Detach caliper from mounts a Remove both mounting screws 5 while supporting caliper above brake rotor b Slowly remove caliper by tilting away from wheel and then pulling away from rotor DISASSEMBLY 1 See Figure 2 30 Remove four screws 3 metric to separate caliper halves 2 Remove two O rings from between caliper halves and discard 3 See Figure 2 31 Use BRAKE CALIPER PISTON REMOVER Part No B 42887 w...

Page 92: ...w O rings 3 between caliper halves 3 Attach caliper halves together with four screws 7 met ric Tighten to 14 5 18 ft lbs 20 24 Nm 4 Install a new bleeder valve 4 metric if necessary Tighten to 3 5 ft lbs 4 7 Nm INSTALLATION 1 Fit front brake caliper on rotor a Check rotor attachment to carrier Inspect all six T 40 TORX screws b Make sure rotor is centered on carrier Use two clamps on rotor and car...

Page 93: ...tall master cylinder cover plastic insert and gasket with two screws Tighten to 9 13 in lbs 1 2 Nm 11WARNING 1WARNING Always test motorcycle brakes at low speed after servic ing or bleeding system To prevent death or serious injury Buell recommends that all brake repairs be per formed by a Buell dealer or other qualified mechanic 9 Depress front brake lever several times to set brake pads to prope...

Page 94: ...der 2 See Figure 2 37 From the master cylinder the brake line runs downward in front of the right handlebar where it turns inboard at the upper triple clamp Loosely install clamp and wire guide 5 with screw 4 to attach front brake line clamp to right side of lower triple clamp Route brake line through wire guide as shown in Figure 2 37 11WARNING 1WARNING Use only new black banjo washers See Parts ...

Page 95: ...eath or serious injury Buell recommends that all brake repairs be per formed by a Buell dealer or other qualified mechanic 7 Install bleeder valve if removed Refill master cylinder and bleed brakes See 1 7 BRAKES 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper brake lamp operation could result...

Page 96: ...pedal turn buckle 4 a Spin locknut 3 away from top surface of turn buckle b Turn rod adjuster 2 to free rod from turn buckle 4 6 See Figure 2 41 Remove screws 2 metric to detach master cylinder 3 from frame 7 See Figure 2 42 Detach remote reservoir a Remove seat b Remove top or bottom clamp on hose connected to master cylinder c Remove screw to detach reservoir from frame if nec essary DISASSEMBLY...

Page 97: ...embly 3 into master cylin der body 1 INSTALLATION 1 See Figure 2 42 Connect remote reservoir a If removed attach remote reservoir to frame using screw Tighten to 12 15 in lbs 1 4 1 7 Nm b Attach line to master cylinder using clamp 2 See Figure 2 41 Attach master cylinder 3 to frame Apply LOCTITE THREADLOCKER 243 blue to both screws 2 metric Tighten to 8 10 ft lbs 11 14 Nm 11WARNING 1WARNING Use on...

Page 98: ...OTRESTS 8 With motorcycle in a level position check that brake fluid is between the upper and lower marks on reservoir Add D O T 4 BRAKE FLUID if necessary Be sure gasket and cap on reservoir fit securely 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper brake lamp operation could result in deat...

Page 99: ...NING Clean brake system components using denatured alco hol Do not use mineral base cleaning solvents such as gasoline or paint thinner Use of mineral base solvents causes deterioration of rubber parts that continues after assembly This may result in improper brake operation which could result in death or serious injury 1 Clean all parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contami...

Page 100: ...anger pin metric Tighten to 11 14 5 ft lbs 15 20 Nm b Install pin plug Tighten to 1 5 2 1 ft lbs 2 3 Nm 4 Install a new bleeder valve metric if necessary Tighten to 3 5 ft lbs 4 7 Nm INSTALLATION 1 See Figure 2 45 Install caliper mount clip 1 if removed 2 See Figure 2 44 Install caliper assembly on caliper mount Brake pad surfaces must face rear brake rotor a Apply LOCTITE THREADLOCKER 272 red to ...

Page 101: ...low speed after servic ing or bleeding system To prevent death or serious injury Buell recommends that all brake repairs be per formed by a Buell dealer or other qualified mechanic 4 Depress rear brake pedal several times to set brake pads to proper operating position within caliper Bleed brake system See 1 7 BRAKES 5 See Figure 2 48 Verify proper fluid level in reservoir 11WARNING 1WARNING Check ...

Page 102: ... rear brake reservoir hose to rear brake line above rear master cylin der on right side of motorcycle 8 See Figure 2 51 Disconnect two wires from rear brake light switch CAUTION Damaged banjo bolt seating surfaces will leak when reassembled Prevent damage to seating surfaces by carefully removing brake line components 9 Remove rear master cylinder banjo bolt and two banjo washers Discard banjo was...

Page 103: ...ng to rear caliper 4 Carefully push up on bottom of oil tank and position rear brake line tangs under studs on the bottom of the oil tank Lower oil tank allowing studs to engage pockets in frame 5 See Figure 2 54 Install loop cushioned clamp to brake line and then to bolt side of tie bar fasteners Loop clamp is oriented down and to the left Install tie bar to frame with bolt washer and loop cushio...

Page 104: ... battery explosion which could result in death or serious injury 15 Connect positive battery cable Tighten to 60 96 in lbs 7 11 Nm 16 Connect negative battery cable Tighten to 60 96 in lbs 7 11Nm 17 Bleed rear brake system and install reservoir cap See 1 7 BRAKES 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shif...

Page 105: ...ws on both the upper and lower triple clamps 7 Remove front forks through bottom of triple clamps DISASSEMBLY NOTE To prevent change in set position of damping force adjuster needle do not loosen the lock nut 1 See Figure 2 55 Loosen the fork bolt 1 metric from the outer tube and slightly compress the fork leg Remove the fork bolt with attached O ring 2 2 See Figure 2 56 Set the FRONT FORK SPRING ...

Page 106: ...t Stopper 4 Spring Collar 5 Spring Joint 6 O Ring 7 Spring 8 Outer Tube 9 Guide Bushing 10 Seal Spacer 11 Oil Seal 12 Stopper Ring 13 Dust Seal 14 Damper Assembly 15 Centering Plate 16 Slide Bushing 17 Slide Pipe 18 Special Washer 19 Center Bolt 20 Mounting Bolt 8 9 10 11 12 13 7 16 18 19 20 b0652x2x 17 14 15 ...

Page 107: ...excessive wear or scratches Replace if damaged or worn 4 Replace the stopper ring 12 if distorted 5 Measure spring 7 free length Replace springs shorter than service wear limit of 9 13 in 232 mm 6 See Figure 2 59 Measure slide pipe runout Replace pipe if runout exceeds the service wear limit of 0 008 in 0 2 mm ASSEMBLY 1 See Figure 2 60 Wrap the end of the slide pipe and the slide bushing channel ...

Page 108: ...13 Pump the piston rod and leg slowly at least 10 times about 6 in 150 mm strokes 14 Place the piston rod and outer tube 8 in the full bot tomed position 15 See Figure 2 62 Pour the recommended fork oil into the slide pipe to a level between the maximum and minimum limits Additional information on setting oil levels can be found under 1 16 FRONT FORK 16 See Figure 2 63 Install the spring with the ...

Page 109: ...lamp Be sure that top surface of fork is not below top surface of upper triple clamp b Position top of headlamp brackets 2 0 in 50 8 mm below upper triple clamp c Tighten large screws to 18 20 ft lbs 24 27 Nm d Tighten small screw to 10 12 ft lbs 14 16 Nm if loosened during fork stem service 4 Install front fender See 2 31 FRONT FENDER 5 Install front wheel See 2 5 FRONT WHEEL 6 Install front brak...

Page 110: ...d its entire circumference until bearing falls free d Remove lower dust shield 3 7 If replacement of bearing cups 5 is necessary drive cups from steering head using STEERING HEAD BEAR ING RACE REMOVER Part No HD 39301A and UNI VERSAL DRIVER HANDLE Part No HD 33416 CLEANING AND INSPECTION See 1 15 SUSPENSION DAMPING ADJUSTMENTS for adjustment procedures 1 See Figure 2 66 Clean the dust shields 3 be...

Page 111: ...on tool 4 Insert lower triple clamp 6 through the steering head Install the upper bearing 4 with small end down and dust shield 3 onto fork stem 5 See Figure 2 68 Apply LOCTITE ANTI SEIZE to fork stem bolt 1 Loosely install upper triple clamp 2 using fork stem bolt 6 Install fork assemblies See 2 16 FRONT FORK 7 Install steering head lock See 2 18 STEERING HEAD LOCK 8 Install instrument support an...

Page 112: ...INSTALLATION 1 Install steering head lock in fork stem a See Figure 2 71 Dished area of steering head lock faces front wheel b Lift front wheel upward c See Figure 2 70 Lock must be in the unlocked posi tion to install Insert lock with key openings posi tioned as shown d Release front wheel 2 Install and adjust handlebars See 1 22 HANDLEBARS 3 See Figure 2 69 Tighten fork stem bolt and triple clam...

Page 113: ... floor hoist placed behind the lift Raise motorcycle off lift until rear suspension is unloaded 6 Remove mounting bolt attaching swingarm to rear shock 7 Remove rear wheel 8 Remove cap from oil tank and drain oil 9 Detach feed line from bottom of oil tank 10 Detach rear brake pedal from master cylinder pushrod 11 Remove left side rider footrest and shifter lever 12 See Figure 2 72 Place a jack und...

Page 114: ...ove roller bearing cups 5 only if replacement is required The complete bearing assembly must be replaced as a unit when replacement is necessary Do not intermix bearing components 3 See Figure 2 76 Carefully press roller bearing cups from swingarm using STEERING HEAD BEARING RACE REMOVER Part No HD 39301A and UNIVERSAL DRIVER HANDLE Part No HD 33416 CLEANING AND INSPECTION 1 Thoroughly clean all c...

Page 115: ...ads on left side of swingarm d Tighten the left pinch screw 4 on the swingarm mount block 5 Do not tighten the right side pinch screw at this time e Insert rod through swingarm into left side bearing adjustment bolt Tighten to an initial torque of 10 13 ft lbs 14 18 Nm INSTALLATION 1 See Figure 2 73 Align new swingarm between posts on swingarm mount block 5 2 Insert left threaded and right bearing...

Page 116: ...h 2 5 quarts 2 37 liters of recommended oil See 1 6 ENGINE LUBRICATION SYSTEM 13 Attach rear brake pedal to master cylinder pushrod 14 Attach left side rider footrest and shifter lever Apply LOCTITE THREADLOCKER 272 red to bolt Tighten bolt to 23 25 ft lbs 31 34 Nm 15 Install rear wheel See 2 6 REAR WHEEL 16 Set axle alignment and belt deflection See 1 11 DRIVE BELT DEFLECTION a See Figure 2 79 Ch...

Page 117: ...he negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 19 Attach both battery cables positive cable first 20 Remove motorcycle from lift 21 Compress suspension to install rear fender and lower belt guard See 2 32 REAR FENDER 22 Check oil level after starting motorcycle and allowing it to reach operating temperature 11WARNING 1W...

Page 118: ...ckwasher and washers from mount block Discard lockwasher 7 See Figure 2 83 Loosen left and right isolator bolts Do not remove 8 See Figure 2 82 Remove two screws locknuts and right side passenger footrest mounting bracket from frame Discard locknuts 9 Remove screw and locknut from rear brake pedal that attaches actuator rod to rear brake master cylinder Dis card locknut 10 Remove two screws that a...

Page 119: ...ent means 6 Apply anti seize to underside of isolator bolt head CAUTION Use caution when installing isolator bolts Make sure iso lator bolt hole is aligned with threaded hole in bearing adjusting bolt to avoid cross threading bolt 7 Install isolator TORX bolt and washer through rubber iso lator into bearing adjustment bolt Do not tighten 8 See Figure 2 82 Install right side plate with three screws...

Page 120: ...RNING 1WARNING 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 18 Install fuel tank fuel tank cover and seat See 4 37 FUEL TANK 19 Connect negative battery cable to negative battery termi nal 11WARNING 1WARNING C...

Page 121: ...tric and locknut from the rear mount Discard locknut 9 Remove shock absorber assembly INSTALLATION 1 See Figure 2 87 Place new bushings into mounting holes of shock absorber if only replacing bushings 2 See Figure 2 86 Loosely install rear allen screw metric and new locknut 3 Loosely install front allen screw metric and new lock nut 4 Install rear clamp over front oil pump fitting 5 Slide reservoi...

Page 122: ...is HOME Figure 2 87 Rear Shock Absorber b0918x2x Rear Reservoir Clamp Front Reservoir Clamp Nylon 40 45 ft lbs 54 61 Nm Front Shock Mount Reservoir Mount Block Metal Locknut 2 30 33 ft lbs 41 45 Nm Washers 3 Locknut 2 Washers ...

Page 123: ... be in good con dition and properly inflated Failure to check the tires could result in death or serious injury See Figure 2 88 See Figure 2 89 The rear suspension adjusts for compression and rebound damping and spring preload See Figure 2 90 The front suspension adjusts for compres sion and rebound damping If the rear preload adjustment is correct and you have the rebound and compression damping ...

Page 124: ...sion damping using the slotted dial on the shaft at the end of the shock Factory setting full damping minus 2 25 turns Adjusting Rear Shock 1 Using a screwdriver turn the slotted dial on the appropriate adjuster clockwise until it stops This is the maximum damping setting for that adjustment 2 Then turn the dial counterclockwise the recommended amount to align the reference marks This is the facto...

Page 125: ...N Pumping on the Rear occurs when you are accelerating out of a corner This problems occurs in two varieties 1 The first type has a movement with a long stroke and a high frequency 2 The second version has a movement with a short stroke and high frequency 1 The shock is too soft Increase compression damping If the adjuster is already set to the max imum add more preload to the spring one turn maxi...

Page 126: ... for the rider s size and weight For information on setting rear shock preload see 1 14 PRELOAD ADJUSTMENT DATE FRONT FORK REBOUND FRONT FORK COMPRESSION REAR SHOCK REBOUND REAR SHOCK COMPRESSION RESULTS Max damping minus 0 5 turn Max damping minus 1 25 turns Max damping minus 1 5 turn Max damping minus 2 25 turns Factory recommended settings ...

Page 127: ... housings 5 9 Throttle control cable 4 has a molded fitting end and is positioned inside the front housing 5 Idle control cable 3 has a smaller fitting end and is posi tioned inside the rear housing 9 2 Run cables inside grooves of each housing 5 9 3 Attach ferrules 7 to cable wheel 8 When properly assembled notches for ferrules will be at 12 o clock 4 Position housings on right handlebar by engag...

Page 128: ...hind the steering head c See Figure 2 95 Route cables below the fuel tank and continue downward 6 Attach throttle cables to throttle body and adjust See 1 20 THROTTLE CABLES See Figure 2 96 Attach throttle cable clamp to fer rules with screw arrow on clamp points up 7 Install air cleaner assembly See 4 42 AIR CLEANER Figure 2 93 Throttle Cable Handlebar Routing 6855 Figure 2 94 Steering Neck Routi...

Page 129: ...Remove O ring 8 from cable end fitting Clutch Hand Control 1 See Figure 2 98 Detach clutch switch 7 a Remove screw 8 b Depress clutch lever and hold c Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar NOTE The individual parts of the clutch switch are not serviceable Replace switch upon failure 2 Remove bolt 2 metric and nut 6 metric 3 Remove han...

Page 130: ...ee Figure 2 98 Attach clutch clamp 5 as follows a Slide clamp over handlebar b Install left switchgear housing See 7 15 HANDLE BAR SWITCHES c Place clamp next to switchgear housing Fasten to handlebar with screw 4 metric Tighten to 30 35 in lbs 3 4 Nm d Install a new left handgrip See 2 27 HANDLE BARS 2 Connect end of clutch cable upper section to clutch han dlever Position lever within clutch cla...

Page 131: ...nstrument support on handlebar clamp Install two screws c Tighten screws to 4 5 ft lbs 5 7 Nm 2 Install odometer reset button 3 Install ignition key switch face nut 3 See 7 3 IGNITION HEADLAMP KEY SWITCH 4 Install indicator lights 5 a Place graphics panel inside indicator light bezel Install parts through front of dash b See Figure 2 101 Align wire colors on indicator light housing with correct sy...

Page 132: ...o 10 12 ft lbs 14 16 Nm c Then tighten both rear screws 2 10 12 ft lbs 14 16 Nm 3 Install clutch hand control See 2 25 CLUTCH CON TROL 4 Install left switch housing See 7 15 HANDLEBAR SWITCHES 5 Check control wire routings a See Figure 2 103 Route right hand control wires 1 in front of handlebar and triple clamp 4 b Route left hand control wires 2 in front of handle bar and triple clamp 4 6 Instal...

Page 133: ... Remove bolts locknuts and washers c Remove nuts and washers securing front muffler support to voltage regulator bracket and crankcase d Remove muffler support Remove front muffler mounts and mount spacer Exhaust Header 1 Remove muffler 2 Remove any restrictive cable straps on oxygen sensor wiring Detach oxygen sensor connector 137 3 See Figure 2 107 Loosen the four exhaust header nuts 20 using SN...

Page 134: ...8 Bolt Washers 2 Metal Locknut Metal Bolts 2 Washer 2 Z Bracket Muffler Voltage Regulator Voltage Regulator Mounting Bracket Header Support Mount Bolts 2 Rear Muffler Mount Bracket Mount Tabs Locknuts 2 Spacer 20 22 ft lbs 27 30 Nm 22 24 ft lbs 30 33 Nm 22 24 ft lbs 30 33 Nm 30 33 ft lbs 41 45 Nm ...

Page 135: ...o not tighten 11WARNING 1WARNING Before tightening muffler hardware position muffler to provide adequate clearance from rear shock absorber side stand spring post and rear tire Failure to provide adequate clearance during motorcycle operation could result in death or serious injury 6 See Figure 2 104 Position muffler and install to rear mounting support and weldnuts in rear muffler straps with two...

Page 136: ...eader to cylinder heads with exhaust header clamps and nuts Tighten nuts to 6 8 ft lbs 8 11 Nm using SNAP ON SWIVEL SOCKET Part No PFSX916 7 Install oxygen sensor to header if removed Apply LOC TITE ANTI SEIZE LUBRICANT to threads of sensor and install to exhaust header Tighten sensor to 42 45 ft lbs 57 61 Nm Attach oxygen sensor connector 137 Secure wiring and sensor with new cable ties 8 Tighten...

Page 137: ...Secure footrest to frame mount with bolt 8 and nut 9 Tighten to 10 15 ft lbs 14 20 Nm 2 Install rider footrest NOTE If footrest mount 6 was removed apply LOCTITE THREAD LOCKER 271 red to bolt install and tighten bolt to 23 25 ft lbs 31 34 Nm a Position spring 4 on mount 6 with thick side of spring inboard b Install pin 3 through spring 4 mount 6 and foot rest 5 c Install washer 2 and retaining rin...

Page 138: ...KER 222 purple to both screws c Install screws to rear of sprocket cover Tighten screws to 12 17 in lbs 1 2 Nm 2 Apply LOCTITE THREADLOCKER 243 blue to screw Install sprocket cover assembly with screw washer and spacer Tighten screw to 48 72 in lbs 5 9 Nm 3 See Figure 2 112 Apply LOCTITE THREADLOCKER 243 blue to bolts 1 Place metal washers 2 over bolts 1 and then install rubber washer 3 Install bo...

Page 139: ...upper fender mounting screws 3 washers 4 wire guides 5 plastic spacers 6 and locknuts 7 5 Carefully remove fender 1 from between front forks 6 Install in reverse order a Tighten upper fender mounting screws 3 to 20 25 in lbs 2 3 Nm b Tighten lower fender mounting screws 8 metric to 10 15 in lbs 1 2 Nm Figure 2 114 Front Fender 1 Front Fender 2 Reflector 2 U S Models 3 Screw 2 4 Washer 2 5 Wire Gui...

Page 140: ...ver tire making sure that the brake line 4 is on the inside of the fender as shown 2 Have someone sit on the vehicle to compress the motor cycle s suspension 3 See Figure 2 116 Install hardware in reverse order Apply LOCTITE THREADLOCKER 243 blue to all screws 4 Attach footrest mounts on both sides Tighten bolts to 13 16 ft lbs 18 22 Nm Figure 2 115 Rear Fender With Brake Line Left Side Figure 2 1...

Page 141: ...ION 1 See Figure 2 118 Position stone guard 4 with wellnuts 5 and lower belt guard 3 on swingarm 2 Secure with two screws 1 and washers 2 Figure 2 117 Belt Guard and Stone Guard Installation Figure 2 118 Stone Guard and Belt Guard Mounting b0612a2x 1 Screw 2 2 Washer 2 3 Lower Belt Guard 4 Stone Guard 5 Wellnut 2 1 4 3 2 5 1 Screw 2 2 Washer 2 3 Lower Belt Guard 4 Stone Guard 5 Wellnut 2 2 1 3 5 4...

Page 142: ...lace LOCTITE THREADLOCKER 243 blue on the last few threads of bolts c Loosely install both bolts 3 See Figure 2 120 Loosely install bolt washer and well nut 1 to attach chin fairing 2 to chin fairing bracket 4 See Figure 2 119 On left side of chin fairing 2 loosely install bolt and washer 1 Loosely install shift lever bolt and washer 4 5 Secure chin fairing hardware a Tighten chin fairing bracket ...

Page 143: ...ellnuts 4 3 Attach vent hose to vent hose fitting with a new cable strap 4 See Figure 2 122 Install bracket a Position bracket 3 over fuel tank cover 4 Tab on bracket must face towards rear wheel b Install two screws 1 and washers 2 Tighten screws to 9 11 ft lbs 12 15 Nm 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it co...

Page 144: ...ON 1 See Figure 2 124 Position air scoop 2 over fuel tank cover 4 2 Fasten air scoop 2 to fuel tank cover 4 using screw and washer 1 and wellnut 3 at front of scoop 3 Install screw and washer into wellnut at bottom of scoop 4 See Figure 2 125 Install screw washer and nut to attach air scoop 1 to clamp 3 Figure 2 124 Air Scoop Figure 2 125 Air Scoop Clamp b0775x2x 1 Screw and Washer 2 Air Scoop 3 W...

Page 145: ...ee Figure 2 126 Position trunk 4 in tail section 5 2 Secure front of trunk 4 to tail section 5 with two screws and washers 1 and washers and nuts 2 3 Secure trunk 4 to tail section 5 with two screws and washers 3 under edge of tail section 4 See Figure 2 127 Secure trunk to license plate bracket 2 with screws and washers 1 5 See Figure 2 128 Attach data link connector 91A to trunk Figure 2 126 Tai...

Page 146: ...olts 20 from the lower frame connection Rotate the tail section upward and remove the two upper nuts washers and bolts CLEANING CAUTION Do not use wheel care products or other compounds developed specifically for cleaning and polishing un coated aluminum These cleaners could potentially dam age the tail section finish The cast aluminum tail section has a clear powdercoat Because the surface is not...

Page 147: ... 6 5 Screw 2 6 Screw 4 7 Nut 4 8 Washer 6 9 Bracket License Plate 10 Nut 2 11 Lock Assembly 12 Holder License Plate 13 Screw 4 14 Tail Section 15 Screw 2 16 Seat 17 Bracket Electronic Control 18 Nut 4 19 Washer 4 20 Screw 4 1 2 3 4 5 9 7 8 10 3 11 12 13 6 14 3 15 16 17 2 8 18 19 20 6 4 b0664x2x ...

Page 148: ...th two screws and washers 10 See Figure 2 132 Install trunk 1 to fit inside of clips Loosely install front bolts 5 nuts 2 and washers 3 4 Loosely install license plate bracket 9 screws 6 and washers 4 finalize trunk alignment Install middle fas teners 6 with washers Tighten all fasteners 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If se...

Page 149: ...ve both windscreen brackets following procedure under 2 16 FRONT FORK INSTALLATION 1 If removed install both windscreen brackets See 2 16 FRONT FORK 2 Align windscreen on right and left brackets 3 See Figure 2 134 Install two screws and nylon washers on each side Tighten securely Figure 2 134 Windscreen Right Side 7060 Screws and Nylon Washers ...

Page 150: ...ure 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 3 Turn ignition key and remove from seat lock ATTACHMENT POINTS CAUTION Helmet hook will not prevent helmet theft See your Buell dealer for helmet locking solutions See Figure 2 136 Two metal hooks cables and locktabs on t...

Page 151: ...dragger 1 INSPECTION 1 Replace dragger when worn to wear line shown in Figure 2 139 2 Test the side stand in the following manner Without vehi cle weight resting on it side stand should move freely into extended down and retracted up positions 3 Check sidestand switch starter interlock for proper operation after the first 500 miles and every 2500 miles thereafter See 7 5 STARTER INTERLOCK ASSEMBLY...

Page 152: ...2 84 2002 Buell X1 Chassis HOME NOTES ...

Page 153: ...3 6 Cylinder and Piston 3 23 3 7 Lubrication System 3 31 3 8 Oil Hose Routing 3 32 3 9 Oil Tank 3 33 3 10 Oil Pressure Indicator Switch 3 34 3 11 Crankcase Breathing System 3 35 3 12 Oiling System Color Foldout 3 36 3 13 Oil Pump 3 37 3 14 Oil Filter Mount 3 40 3 15 Hydraulic Lifters 3 41 3 16 Gearcase Cover and Cam Gears 3 43 3 17 Crankcase 3 50 Table Of Contents ...

Page 154: ......

Page 155: ...C Exhaust 52 BBDC 24 ATDC ENGINE IGNITION SPECIFICATIONS Type Sequential non waste spark Regular Idle 850 1050 RPM Spark Plug Size 12 mm Spark Plug Type Harley Davidson No 10R12 Spark Plug Gap 0 038 0 043 in 0 97 1 09 mm Spark Plug Torque 11 18 ft lbs 15 24 Nm VALVE NEW COMPONENTS SERVICE WEAR LIMITS Fit in guide Exhaust 0 0015 0 0033 in 0 0381 0 0838 mm 0 0040 in 0 1016 mm Intake 0 0008 0 0026 in...

Page 156: ...mm 0 065 in 1 651 mm Compression ring side clearance Top 0 0020 0 0045 in 0 0508 0 1143 mm 0 0065 in 0 1651 mm 2nd 0 0016 0 0041 in 0 0406 0 1041 mm 0 0065 in 0 1651 mm Oil control ring side clearance 0 0016 0 0076 in 0 0406 0 1930 mm 0 0094 in 0 2388 mm Pin fit loose at room temperature 0 00005 0 00045 in 0 00127 0 01143 mm 0 00100 in 0 02540 mm CYLINDER HEAD NEW COMPONENTS SERVICE WEAR LIMITS Va...

Page 157: ...E WEAR LIMITS Cam gear shaft in bushing loose 0 0007 0 0022 in 0 0178 0 0559 mm 0 003 in 0 076 mm Cam gear shaft end play min except rear intake 0 005 0 024 in 0 127 0 610 mm 0 025 in 0 635 mm Rear intake cam gear shaft end play min 0 006 0 024 in 0 152 0 610 mm 0 040 in 1 016 mm FLYWHEEL NEW COMPONENTS SERVICE WEAR LIMITS Runout Flywheels at rim 0 000 0 010 in 0 000 0 254 mm 0 010 in 0 254 mm Sha...

Page 158: ...lt Front 100 110 ft lbs 136 149 Nm page 3 10 Isolator TORX Bolts Rear 63 70 ft lbs 85 95 Nm LOCTITE THREADLOCKER 262 red and ANTI SEIZE under bolt heads special pro cedure page 3 10 Oil Filter Adapter 8 12 ft lbs 11 16 Nm LOCTITE THREADLOCKER 243 blue to mount side only page 3 40 Oil Pressure Indicator Switch 50 70 in lbs 6 8 Nm page 3 40 Oil Pump Cover TORX Screws 70 80 in lbs 8 9 Nm page 3 39 Oi...

Page 159: ...e 91 pump octane or higher Some fuel suppliers sell gasoline alcohol blends as a fuel The type and amount of alcohol added to the fuel is important DO NOT USE GASOLINES CONTAINING METHANOL Using gasoline methanol blends will result in starting and driveability deterioration and damage to critical fuel sys tem components ETHANOL is a mixture of 10 ethanol Grain alcohol and 90 unleaded gasoline Gaso...

Page 160: ...gh the process of elimination to indicate any one of the above components is worn it is best to give attention to all of the cylinder head and cylinder parts Compression Test Procedure Combustion chamber leakage can result in unsatisfactory engine performance A compression test can help determine the source of cylinder leakage Use CYLINDER COMPRES SION GAUGE Part No HD 33223 1 A proper compression...

Page 161: ... lock the rear brake 7 Following the manufacturer s instructions perform a cyl inder leakage test on the front cylinder Make a note of the percent leakdown Any cylinder with 12 leakdown or more requires further attention 8 Listen for air leaks at intake exhaust head gasket and timing inspection hole See Table 3 2 NOTE If air is escaping through valves check push rod length 9 Repeat procedure on re...

Page 162: ...ket 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...

Page 163: ...ubber isolators 5 can be removed Frame will rise while engine remains secured to lift by crating strap NOTE Rubber isolators align with a frame mounted metal pin 20 Raise frame and walk forward over and away from the engine 21 If necessary remove rear swingarm assembly See 2 19 SWINGARM 22 If necessary detach swingarm mount block from power train by removing bolts 3 4 washers and locknuts Figure 3...

Page 164: ...ake line 9 See Figure 3 4 Place clutch cable clamp 3 on front tie bar bolt 2 Clamp should hold cable on primary cover side of motor Insert bolt from front through frame and install washer 4 Continue through tie bar 1 and frame Install locknut 5 and tighten to 30 33 ft lbs 41 45 Nm 10 Attach front upper tie bar 11 Insert bolt through tie bar front isolator and frame Secure with nut and washer Tight...

Page 165: ...esulting sparks may cause a battery explo sion which could result in death or serious injury 7 Install battery Connect both battery cables positive cable first 1WARNING 1WARNING 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 s...

Page 166: ...ashers 14 b Remove three bolts and washers 15 c Remove the two rocker arm retaining bolts 12 near the push rods d Remove the remaining two rocker arm retaining bolts 13 5 Remove lower rocker cover 18 NOTE Remove lower rocker boxes as an assembly then disassem ble as required 6 Mark the location and orientation top bottom of each push rod Remove push rods CAUTION Mark rocker arm shafts for reassemb...

Page 167: ...forming the next steps 11 Remove nut washer and bolt to detach front upper tie bar from isolator and frame 12 Continue loosening in 1 8 turn increments until screws are loose Remove head screws 13 See Figure 3 10 Remove cylinder head 18 head gas ket 4 and O rings 14 NOTE Front cylinder head must be removed through upper triangu lar frame members with front isolator mount attached 14 Remove both pu...

Page 168: ...e head Remove valve 10 valve stem seal 11 and lower collar 9 5 Repeat the above procedure for the other valve 6 Disassemble the other head using the same procedure Figure 3 10 Cylinder Head Cylinder and Piston 18 7 8 5 6 11 9 16 17 10 14 2 10 12 4 13 19 3 15 17 8 5 7 1 16 5 6 11 9 20 1 Head Screw Long 2 2 Head Screw Short 2 3 Arrow Piston Direction 4 Head Gasket 5 Inner Valve Spring 2 6 Outer Valv...

Page 169: ...ng Replace rocker arm if either condition exists 5 Measure and record rocker arm shaft diameter a See Figure 3 12 Measure where shaft fits in lower rocker arm cover b See Figure 3 13 Measure where rocker arm bush ings ride 6 Measure and record rocker arm shaft bore diameter a See Figure 3 14 Measure bore of lower rocker cover b See Figure 3 15 Measure rocker arm bushing inner diameter 7 Check the ...

Page 170: ... Check free length and compression force of each spring Compare with SERVICE WEAR LIMITS If spring length is shorter than specification or if spring compression force is below specification replace spring 18 Examine push rods particularly the ball ends Replace any rods that are bent worn discolored or broken 19 See Figure 3 17 Check head gasket surface on head for flatness Machine or replace any h...

Page 171: ...t the correct guide height has been reached 5 Ream guides to final size or within 0 0010 in 0 0254 mm of final size using VALVE GUIDE REAMER Steel Part No HD 39932 or Carbide Part No HD 39932 CAR Use REAMER LUBRICANT Part No HD 39964 or liberal amounts of suitable cutting oil to pre vent reamer chatter 6 Apply the proper surface finish to the valve guide bores using the VALVE GUIDE HONE Part No HD...

Page 172: ...ut the seats See Figure 3 22 Always grind valves before cutting seats 1 Cut 46 or grind 45 valve seat angle first Use cutting oil to avoid chatter marks Cut or grind only enough to clean up the seat 2 Apply a small amount of lapping compound to the valve face Rotate valve against seat using VALVE LAPPING TOOL Part No HD 96550 36A 3 See Figure 3 21 Check the contact pattern on valve face It should ...

Page 173: ...aces and Seats NOTE If valve faces and seats have been smoothly and accurately refaced very little lapping will be required to complete the seating operation 1 See Figure 3 24 Use CYLINDER HEAD HOLDING FIX TURE 2 Part No HD 39786 to secure cylinder head a Apply a light coat of fine lapping compound to valve face Insert valve in guide b Place one rubber cup end of VALVE LAPPING TOOL 1 Part No HD 96...

Page 174: ...s the lower collar 8 See Figure 3 10 Install valve springs 5 6 and upper collar 8 9 Compress springs with VALVE SPRING COMPRESSOR Part No HD 34736B 10 Insert valve keepers 7 into upper collar 8 making sure they engage groove in valve stem The keeper gaps should be equal 11 Release and remove VALVE SPRING COMPRESSOR 12 Repeat Steps 4 11 for the remaining valve s 1WARNING 1WARNING Always wear proper...

Page 175: ...tening the head screws is critical to proper distribution of pressure over gasket area It prevents gasket leaks stud failure and head and cylin der distortion 10 See Figure 3 8 For each cylinder head start with screw numbered one as shown In increasing numerical sequence i e 1 2 3 and 4 a Tighten each screw to 8 10 ft lbs 11 14 Nm b Tighten each screw to 13 15 ft lbs 18 20 Nm c Loosen all screws 1...

Page 176: ...AP ON Part No FRDH 181 and TORQUE COMPUTER SNAP ON Part No SS 306G to correctly assemble 16 See Figure 3 29 Install middle and upper rocker covers a Place a new gasket 7 on lower rocker box assem bly b Install middle rocker cover 5 with umbrella valve next to intake manifold c Place a new gasket 6 on middle rocker cover d Install upper rocker cover 4 using screws with washers 1 and new fiber seals...

Page 177: ...nd lead to stud failure 7 Install a 6 0 in 152 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the pistons 1WARNING 1WARNING Always wear proper eye protection when removing the compression rings Slippage may propel the ring with enough force to cause an accident This could result in death or serious injury CAUTION The piston pin retaini...

Page 178: ... in 0 03175 0 04445 mm clearance in bushing b If piston pin to bushing clearance exceeds 0 00200 in 0 05080 mm replace worn parts See CON NECTING ROD BUSHING on page 3 28 6 Clean piston pin retaining ring grooves 7 Examine piston and cylinder for cracks burnt spots grooves and gouges 8 Check connecting rod for up and down play in lower bearings When up and down play is detected lower bearing shoul...

Page 179: ...ds service limit cylinders should be rebored and or honed to next standard oversize and refitted with the corresponding piston and rings Do not fit piston tighter than 0 0007 in 0 0178 mm See 3 1 SPECIFICA TIONS Measuring Piston Because of their complex shape the pistons cannot be accu rately measured with standard measuring instruments The pistons have the typical elliptical shape when viewed fro...

Page 180: ... in the two upper piston ring grooves The dot on the second compression ring must face upward Ring sets are available to fit standard and oversize pistons Piston ring sets must be properly fitted to piston and cylinder 1 See Figure 3 36 Place piston in cylinder about 1 2 in 12 7 mm from top Set ring to be checked squarely against piston as shown Check end gap with thickness gauge See 3 1 SPECIFICA...

Page 181: ...g rings NOTE Install second compression ring with dot towards top 3 See Figure 3 38 Install rings so end gaps of adjacent rings are a minimum of 90 apart Ring gaps are not to be within 10 of the thrust face centerline 4 See Figure 3 39 Check for proper side clearance with thickness gauge as shown See 3 1 SPECIFICATIONS for tolerance NOTE If the ring grooves are clean and the side play is still not...

Page 182: ...must be attached facing the opposite direction as it was for removal of the bushing 8 Clean up and size bushing to 0 0010 0 0005 in 0 0254 0 0127 mm undersize using REAMER Part No HD 94800 26A Sizing bushing with less than 0 00125 in 0 03175 mm clearance can result in a bushing loosening and or seized pin in rod 9 Hone bushing to final size using WRIST PIN BUSHING HONE Part No HD 35102 Use a liber...

Page 183: ... be fully seated in the groove with the gap away from the slot at the bottom 5 See Figure 3 38 Make sure the piston ring end gaps are properly positioned as shown 6 Remove PISTON SUPPORT PLATE 3 Part No HD 42322 7 Lubricate cylinder wall piston pin and rod bushing with engine oil 8 Turn engine until piston is at top dead center 9 See Figure 3 44 Compress the piston rings using PIS TON RING COMPRES...

Page 184: ...3 30 2002 Buell X1 Engine HOME NOTES ...

Page 185: ... particu lates When first starting and warming an engine some of the water vapor that gets into the engine crankcase condenses to form liquid water If the engine is driven long enough to thor oughly warm the crankcase most of this liquid water is again vaporized and exhausted through the crankcase breather system A moderately driven vehicle making short runs may not be able to vacate water vapors ...

Page 186: ...e feed hose attaches to the rear most oil pump fitting the return hose connects forward and above To prevent unnecessary wear the hoses have a fitted cover After diverging from the feed and return hoses the vent hose is routed beneath the starter It continues on to the right side of the motorcycle See Figure 3 47 Here the vent hose 1 connects to an elbow fitting 3 on the gearcase cover 4 Figure 3 ...

Page 187: ...BLY INSTALLATION 1 See Figure 3 49 Place oil tank on frame and align mounts Loosely install bolts and lockwashers 1 2 Connect the four oil tank hoses Tighten new clamps using HOSE CLAMP PLIERS Part No HD 41137 NOTE Clamp may be reused on feed hose 3 at oil tank connection 3 Fill oil tank See 1 6 ENGINE LUBRICATION SYSTEM 4 Attach tail section See 2 38 TAIL SECTION 1WARNING 1WARNING After installin...

Page 188: ... As the engine warms to normal operating temperature the engine oil will warm up and become less viscous oil pressure decreases When an engine is operated at high speeds the volume of oil circulated through the oiling system increases resulting in higher oil pressure As engine speed is reduced the volume of oil pumped is also reduced resulting in lower oil pressure To check oil pressure use OIL PR...

Page 189: ... the crankcase air collects and passes through a small drain hole 2 where it eventually returns to the crankcase The crankcase air is routed through a passage in each cylin der head The air then travels through each air cleaner breather bolt 4 Hoses leading from the air cleaner bolts deposit the air inside the air cleaner s snorkel Figure 3 52 Crankcase Breathing System Typical Cylinder 1 Push Rod...

Page 190: ...gearcase cover Oil flow is then routed to the crankshaft area 10 Oil enters a hole in the end of the pinion gear shaft and travels to the right flywheel where it is routed through the flywheel to the crankpin Oil is forced through the crank pin to properly lubricate the rod bearing assembly 11 Oil flows up passages in the push rods to the rocker arm shafts and bushings 12 The valve stems are lubri...

Page 191: ... the oil tank enters the pump through the feed hose connector 5 It is forced by the gerotor feed set 7 through a hose to the oil filter Return oil from the flywheel compartment is drawn back into the pump and is forced by the gerotor scavenge set 9 back to the oil tank See INTERNAL ENGINE PASSAGES for oil passages within the engine The oil pump seldom needs servicing Before you disassem ble an oil...

Page 192: ...r 6 off body 12 Remove and discard O ring 14 7 Slide both pieces of gerotor feed set 7 separator plate 8 and both pieces of gerotor scavenge set 9 off gear shaft 11 8 Remove and discard retaining ring 16 Remove thrust washer 15 and gear shaft 11 Figure 3 54 Oil Pump Hardware 3 2 1 1 4 5 7068 2 6 1 Mounting Screw and Washer 2 2 Cover TORX Screw 2 3 Feed Hose Connection 4 Return Hose Connection 5 Oi...

Page 193: ...venge set 9 over gear shaft 3 Place outer gerotor over inner gerotor to complete scav enge set 9 4 See Figure 3 57 Install gerotor separator plate 1 by lin ing up slots 2 on perimeter with tabs 3 inside oil pump body 5 Install a new O ring 4 into groove in pump body 6 See Figure 3 55 Place gerotor feed set 7 over gear shaft 11 7 Place cover onto pump body Install cover TORX screws 2 Tighten screws...

Page 194: ...ssed air ASSEMBLY NOTE Use TEFLON PIPE SEALANT or HYLOMAR on all fittings installed to oil filter mount 1 Install oil pressure indicator switch 6 using OIL PRES SURE SENDING UNIT WRENCH Part No HD 41675 Tighten to 4 6 ft lbs 5 8 Nm NOTE The filter adapter 1 has identical ends either end may be installed into the filter mount 4 2 Apply LOCTITE THREADLOCKER 243 blue to the threads on that end of the...

Page 195: ...ead 3 See Figure 3 61 Remove both push rod covers 4 a Remove screw 8 and washer 10 b Lift retainer 6 and seal 7 upward a few inches on push rod cover 4 c Push upward on push rod cover while pulling bottom of cover clear of crankcase Remove cover 4 Remove both hydraulic lifters 3 a Remove two anti rotation screws with washers 2 b Remove lifters 3 from crankcase bore using a thin bladed screwdriver ...

Page 196: ...m 5 Install push rod covers a Slide new seal 5 and retainer 6 over top of push rod cover 4 b Position new O ring 7 at top of push rod cover c Hold cover at an angle and insert top through hole in cylinder head Push up on cover while aligning bot tom of cover with lifter bore in crankcase d Lower retainer 6 with seal 5 onto crankcase aligning locating pin 11 with hole in retainer e Insert screw 8 w...

Page 197: ...l inspection procedures and how components interact Figure 3 62 Gearcase and Valve Train Components 1 Rear Exhaust Cam Gear 2 Rear Intake Cam Gear 3 Front Intake Cam Gear 4 Front Exhaust Cam Gear 5 Pinion Gear 6 Seal 7 Front Intake Cam Gear Bushing 8 Front Exhaust Cam Gear Bushing 9 Gearcase Cover Gasket 10 Right Crankcase Half 11 Nut 12 Oil Pump Drive Gear 13 Cam Gear Bushing 4 14 Rear Exhaust Ca...

Page 198: ...roughly clean gearcase compartment gearcase cover and gears in solvent to remove oil and carbon deposits 2 Blow out all cover oil passages and bushings with com pressed air 3 Clean old gasket material from gearcase and cover faces with cleaning solvent Cam and Pinion Gear Identification See Figure 3 63 Cam lobes are stamped with the number 15 followed by a number 1 2 3 or 4 The number 15 indi cate...

Page 199: ... o clock position within the gearcase cover bore 2 After you install a new bushing in gearcase cover line ream the bushing to correct size See CAM BUSHING REAMING GEARCASE COVER 3 See Figure 3 62 Rear intake cam gear bushing 15 must be installed in its gearcase cover 17 bore using an arbor press You will need to orient the bushing in a specific position of rotation within the cover bore and will n...

Page 200: ...shing in gearcase cover line ream the bushing to the correct size See PINION SHAFT BUSHING REAMING GEARCASE COVER Bushing Reaming NOTE Installing and reaming crankcase and gearcase cover bushings may alter the center distances between mating gears and may result in an increase in gear noise For quiet running gears the gears should be matched to the center distances Bushings in right crankcase half...

Page 201: ... one of the bushings to be reamed in gearcase cover 3 Turn reamer clockwise through bushing in cover until reamer bottoms Then give reamer one complete clock wise turn to size the bushing Continue turning reamer clockwise while extracting reamer from bushing 4 Repeat Steps 2 and 3 for remaining two cam gear bush ings except rear intake bushing in gearcase cover if required 5 Separate gearcase cove...

Page 202: ...ughly clean gearcase cover removing all metal chips shavings Blow out all oil passages using compressed air ASSEMBLY INSTALLATION 1 See Figure 3 71 Install oil pump drive gear 5 and pin ion gear on pinion shaft a Slide oil pump gear drive gear 5 over pinion shaft 1 Drive gear must align with shaft key 4 b Align keyway 3 in ID of pinion gear with shaft key 4 c Slide pinion gear over shaft key 4 and...

Page 203: ...ar being checked is pointing toward its respective lifter guide hole b Gently pry the cam gear toward the gearcase cover using a flat blade screwdriver c Measure gap between bushing in crankcase half and cam gear shaft thrust face shoulder using a feeler gauge This is cam gear end play d Compare cam gear end play measurements with the SERVICE WEAR LIMITS Make repairs as required if end play does n...

Page 204: ...curate flywheel end play reading preload sprocket shaft bearings Create a suitable tool by weld ing two handles to an old engine sprocket nut Install the nut and sprocket Tighten to 190 210 ft lbs 258 285 Nm 5 Check flywheel end play a Rotate and push on sprocket shaft while reading dial indicator b Then rotate and pull on sprocket shaft while reading dial indicator c Replace bearing inner shim Se...

Page 205: ... primary drive clutch compo nents See PRIMARY CHAIN DRIVE under 6 5 PRI MARY DRIVE CLUTCH 6 Remove starter motor See 5 7 STARTER 7 Remove transmission See 6 7 TRANSMISSION CASE 8 See Figure 3 76 Remove screws and rear engine mount bolt securing crankcase halves together 9 Position crankcase on work bench gearcase side up Tap crankcase with plastic mallet to loosen top half and separate the halves ...

Page 206: ... 11 Gearshaft bearing will remain on flywheel pinion shaft Remove retaining ring and bearing may be slipped off pinion shaft 12 See Figure 3 79 Place flywheel assembly in FLYWHEEL FIXTURE Part No HD 44385 Pull sprocket shaft bear ing with SPROCKET SHAFT INNER TIMKIN BEARING REMOVER Part No HD 44404 and ALL PURPOSE CLAW PULLER Part No HD 95635 46 using bolts in place of jaws Insert a penny or suita...

Page 207: ...ws on the retaining ring e See Figure 3 82 Inserting the tips of a large retain ing ring pliers Snap On PR 56A into one hole in each claw compress the retaining ring and remove it from the crankcase bore f Loosen allen head screws and remove claws from retaining ring Figure 3 79 Removing Sprocket Shaft Inner Timken Bearing Typical Figure 3 80 Sprocket Shaft Outer Race Removal 8203 1 1 All Purpose ...

Page 208: ...d have no apparent wear the same set may be reinstalled Make certain all parts of bearing are installed in exactly the same order in which they were removed If any part of bearing assembly is worn entire assembly should be replaced Fitting Pinion Bearings See Figure 3 78 A pressed in bushing in the right crankcase half is the outer race The inner race is pressed on the pinion shaft See Figure 3 86...

Page 209: ...ory as shown See Figure 3 85 Outer races are identified at the factory as shown NOTE The different sizes of crankcase sets and flywheel assem blies will not have separate part numbers That is a replace ment crankcase set may have a class 1 2 or 3 pinion outer race Replacement flywheel assemblies will have either a class A or B inner race See Figure 3 88 Pinion bearings are identified as shown Figu...

Page 210: ...lign with left case bearing and to meet the following specifications See LAPPING ENGINE MAIN BEARING RACES ID 1 5646 1 5652 in 39 7408 39 7561 mm Roundness within 0 0002 in 0 0051 mm Taper within 0 0002 in 0 0051 mm Surface finish 16 RMS 7 See Figure 3 86 Pull inner race from pinion shaft using TWO CLAW PULLER Part No HD 97292 61 CENTER CAP Part No HD 95652 43A and BEARING SEPARA TOR SNAP ON TOOLS...

Page 211: ...tion where hole is larger at ends than it is in the center 4 Withdraw arbor far enough to coat lightly with 220 grit lapping compound Do not apply a heavy coat Reposi tion lap in bushing and turn handle at moderate hand speed Work lap back and forth in bushing as it is revolved to avoid grooving and tapering At frequent intervals remove lap from crankcase wash and inspect bushing Lapping is comple...

Page 212: ...ue White Gray Green 1 5656 1 5658 in 39 766 39 771 mm Red Blue White Gray Green 1 5654 1 5656 in 39 761 39 766 mm Red Blue White Gray Green 1 5652 1 5654 in 39 756 39 761 mm Red Blue White Gray Green 3 1 5650 1 5652 in 39 751 39 756 mm Red Blue White Gray Green 2 1 5648 1 5650 in 39 746 39 751 mm Blue White Gray Green 1 1 5646 1 5648 in 39 741 39 746 mm White Gray Green INNER RACE OD In 1 2496 1 2...

Page 213: ...earings into left crankcase half 6 Always install left outer race 4 prior to installing right outer race 5 because the installer base 1 is usable only when you follow this sequence of race installation 2 Insert SPORTSTER end of installer base 1 into inboard side of left crankcase half 6 bearing bore until base contacts installed retaining ring 3 3 Position left outer race 4 over bearing bore on ou...

Page 214: ...e until bearing firmly con tacts inner spacer Inner and outer bearings must be tight against inner spacer for correct bearing clear ance Remove tool from sprocket shaft f Spin crankcase half to verify that flywheel assembly is free 10 See Figure 3 95 Install new spacer in seal ID With the open lipped side facing outward center seal spacer assembly over bearing bore CAUTION Do not remove the spacer...

Page 215: ...reaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 15 Install pistons and cylinders See 3 6 CYLINDER AND PISTON 16 Install oil pump See 3 13 OIL PUMP 17 Install cam gears gearcase cover lifter guides and lift ers See 3 16 GEARCASE COVER AND CAM GEARS 18 Install cylinder heads See 3 5 CYLINDER HEAD 19 Install starter See 5 7 STARTER 20 Install transm...

Page 216: ...3 62 2002 Buell X1 Engine HOME NOTES ...

Page 217: ... 41 4 17 Trouble Code 11 4 45 4 18 Trouble Code 13 4 49 4 19 Trouble Code 14 4 54 4 20 Trouble Code 15 4 58 4 21 Trouble Code 16 4 62 4 22 Trouble Codes 23 and 32 4 66 4 23 Trouble Codes 24 and 25 4 70 4 24 Trouble Code 33 4 73 4 25 Trouble Code 35 4 76 4 26 Trouble Code 44 4 79 4 27 Trouble Codes 52 53 54 and 55 4 83 4 28 Trouble Code 56 4 84 4 29 Electronic Control Module 4 88 4 30 Cam Position ...

Page 218: ...4 39 Inline Fuel Filter 4 106 4 40 Fuel Pump 4 107 4 41 Throttle Body and Intake Manifold 4 109 4 42 Air Cleaner 4 113 4 43 Evaporative Emissions Control California Models 4 115 ...

Page 219: ... Cap Flange Screws 16 18 in lbs 1 8 2 0 Nm special pattern to tighten page 4 102 Fuel Filter Bracket Bolt 30 33 ft lbs 41 45 Nm page 4 106 Fuel Pressure Regulator Screws 15 20 in lbs 1 7 2 3 Nm page 4 108 Fuel Pump Mounting Nuts 68 75 in lbs 8 9 Nm LOCTITE THREADLOCKER 243 blue special tightening procedure page 4 108 Fuel Tank Mounting Screws 9 11 ft lbs 12 15 Nm page 4 103 Fuel Tank Vent Valve Fi...

Page 220: ...4 2 2002 Buell X1 Fuel System HOME NOTES ...

Page 221: ...to adjust for all possible operating con ditions High lift cams make it necessary for an open loop system at idle and at wide open throttle During open loop operation the system utilizes programmed fuel and spark maps in the ECM which provide stable idle and ease of cold starting and maximum power at wide open throttle WOT During closed loop operation the system relies on input from the O2 sensor ...

Page 222: ...N Switch IGN Relay Cam Sensor TP Sensor IAT Sensor Main Circuit Breaker Battery ET Sensor O2 Sensor Fuel Pump Front Injector Rear Injector Check Engine Lamp Tach Bank Angle Sensor Dual Coil Front Rear Ground Scanalyzer Electronic Control Module ECM one 12 place black connector 10 one 12 place gray connector 11 WIRE COLOR CODES USED IN THIS DOCUMENT LT Light GY Gray V Violet BK Black O Orange W Whi...

Page 223: ...rting or performance prob lems RESOLVING PROBLEMS To resolve system problems five basic steps are involved In order of occurrence they are 1 Check for trouble codes by observing check engine lamp See 4 4 CHECKING FOR TROUBLE CODES 2 Retrieve trouble codes using SCANALYZER Part No HD 41325 or check engine lamp diagnostics See 4 5 SCANALYZER 4 6 CHECK ENGINE LAMP DIAGNOS TICS and Figure 4 3 3 Diagno...

Page 224: ...ed functional trouble codes currently detected by the ECM b The lamp stays off for only four seconds and then comes back on for an eight second period This indi cates a functional error code is stored but no cur rent trouble code exists c If the lamp remains on beyond the eight second period then a current trouble code exists 3 See CODE TYPES for a complete description of trouble code formats NOTE...

Page 225: ...he ECM trouble codes 52 through 55 or with the camshaft sensor timing trouble code 56 RET RIEVING TROUBLE CODES The fuel injection system provides two levels of diagnostics The most sophisticated mode employs a portable diag nostic tool called a Scanalyzer This device plugs into the motorcycle wiring harness It facilitates the diagnosis of system problems through a direct interface with the ECM Se...

Page 226: ... 99 are avail able proceed as follows 1 Turn ignition light key switch OFF 2 Remove seat See 2 40 SEAT 3 See Figure 4 6 Locate the data link connector 91A in the trunk 4 Remove rubber protective plug from data link connector Plug Scanalyzer into connector If necessary detach connector from frame 5 Turn ignition light key switch ON Set engine stop switch to RUN but do not start engine 6 See Figure ...

Page 227: ...ont Coil 5 Rear Coil 6 Tachometer DIAGNOSTIC MENU 1 System ID 2 Trouble Codes 3 Data Monitor 4 Active Diagnostic 5 Special Tests 6 Tool Setup 7 Calibrations MODE MODE MODE MODE MODE MODE 1 2 3 4 5 6 Main Menu Secondary Menus DATA MONITOR MENU 7 CALIBRATION MENU 1 TPS Zero Function 2 AFV Reset MODE RPM 0 ADVANCE F 0 0 DEG ADVANCE R 0 0 DEG ET 14 F ET 4 98 V IAT 76 F IAT 3 75 V O2 0 00 V A F RATIO O...

Page 228: ...gram the mode key need only be pressed once or twice to return to the main menu 4 After correcting system problems clear trouble codes using the trouble codes menu of the scanalyzer Clearing Codes Unlike the check engine lamp diagnostics note that the Scanalyzer does allow the operator to clear trouble codes from memory as well as differentiate between current and historic codes Trouble codes cann...

Page 229: ...ngth of time the lamp is illuminated and the length of time in which it is off are each about 1 second in duration 5 The second digit follows a Following transmission of the first digit there is another 2 second pause in which the lamp is off b The lamp will then flash one or more times to indi cate the second digit of the trouble code Count the number of times the lamp flashes to retrieve the sec...

Page 230: ...and run when the trouble codes are received using a jumper wire on Pins 1 and 2 of the data link connector However if the jumper wire is removed with the engine running the check engine lamp will continue to flash trouble codes To stop check engine lamp from flashing codes turn engine stop switch OFF CLEARING CODES After correcting system problems clear trouble codes If the Scanalyzer is not avail...

Page 231: ...tach gray connector from Breakout Box to corre sponding gray ECM connector b Attach gray connector from the wiring harness to gray connector on Breakout Box REMOVAL 1 See Figure 4 14 Depress latches on each side of con nectors 10 black and 11 gray 2 Detach Breakout Box connectors from ECM connectors 3 Detach Breakout Box connectors from wiring harness 4 Reattach ECM connectors to wiring harness 1W...

Page 232: ...en a cur rent trouble code is detected See Figure 4 15 NOTE If a current trouble code is present when the wiggle test is entered the Scanalyzer will respond as described immedi ately upon entering the wiggle test mode With key ON and engine off clear trouble codes and then perform wiggle test with vehicle running Using DVOM Part No HD 39978 1 See Figure 4 16 Connect DVOM to wiring harness between ...

Page 233: ...ICS General Information The diagnostic check is an organized approach to identifying a problem caused by an electronic control system malfunc tion If no problems are found after completion of the diagnos tic check a comparison of Scanalyzer parameters may be used to help locate intermittents and out of specification sen sors See Table 4 1 Diagnostic Tips If the Scanalyzer is not working properly c...

Page 234: ...l 4 16 MISFIRE Leaky injectors Test fuel injectors See 4 41 THROTTLE BODY AND INTAKE MANIFOLD Valve sticking See Section 3 Table 4 3 Engine Performance Problems SYMPTOM SOLUTION Engine temperature circuit 4 19 TROUBLE CODE 14 CMP circuit 4 28 TROUBLE CODE 56 Spark plugs and or wires 4 16 MISFIRE Improper fuel pressure 4 14 FUEL PRESSURE TEST Improper TP sensor adjustment Calibrate sensor See 4 36 ...

Page 235: ...sensor 4 20 TROUBLE CODE 15 16 Battery voltage 4 21 TROUBLE CODE 16 23 Front fuel injector 4 22 TROUBLE CODES 23 AND 32 24 Front ignition coil 4 23 TROUBLE CODES 24 AND 25 25 Rear ignition coil 4 23 TROUBLE CODES 24 AND 25 32 Rear fuel injector 4 22 TROUBLE CODES 23 AND 32 33 Fuel pump 4 24 TROUBLE CODE 33 35 Tachometer 4 25 TROUBLE CODE 35 44 Bank angle sensor 4 26 TROUBLE CODE 44 52 53 54 55 ECM...

Page 236: ...witch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 Lt GN R V R Data Link 91A Lt GN R V R BK GY GY Table 4 6 Wire Harness Connectors in Figure 4 17 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place Deutsch under seat 91A Data link 4 place Deutsch behind right sid...

Page 237: ...START NO YES NO Are any trouble codes displayed YES Compare scan data with Table 4 1 Are values normal or within typical ranges NO Refer to applicable trouble code flow chart Start with lowest trouble code All diagnostic codes are listed on page 4 17 in Table 4 5 YES Go to Diagnostic Check Part 2 of 2 YES See 4 8 WIGGLE TEST If Wiggle Test does not recreate condition refer to symptoms tables NO Re...

Page 238: ...nk connector terminals against their ECM connector pins for continuity Continuity present in all four circumstances DATA LINK TERMINAL ECM TERMINAL Pin Wire Color Pin Connector 1 Lt GN R 11 11B 2 BK 11 10B 3 V R 12 11B 4 GY 1 10B NO Repair short to ground YES Check Scanalyzer on another vehicle Scanalyzer OK YES Inspect terminals for damage or repair opens as necessary NO YES Scanalyzer malfunctio...

Page 239: ...1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 black pin probe and patch cord 2 See Figure 4 19 Inspect connector 10 black for con tamination or corrosion If connection is good replace ECM See 4 29 ELECTRONIC CONTROL MODULE 3 Check continuity between instrument connector 39 Pin 8 and ECM connector 10 black Pin 4 a Gain access to tachometer cover by removing wind screen b Remove tachometer cover...

Page 240: ... Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 Instruments 39 Tachometer O BK Y Check Engine Lamp O BK Y BK Y GY Table 4 7 Wire Harness Connectors in Figure 4 21 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 39 Main harness to instruments 10 place Multilock und...

Page 241: ...to 4 13 NO ECM POWER NO Refer to 4 12 ENGINE CRANKS BUT WILL NOT START for no start condition and then return to 4 10 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON to resolve no engine check lamp YES NO Disconnect instruments connector 39 Remove BK Y wire from connector 39 and ground it Reconnect connector 39 Check engine lamp ON YES Repair open or short to voltage on BK Y wire between connector 39...

Page 242: ...for four seconds It may then come back on for an eight second period for a stored error or remain on continuously current error DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 10 flow chart 1 See Figure 4 23 If the lamp goes off when the black ECM connector 10 is unplugged the BK Y wire is not shorted to ground Figure 4 22 Check Engine Lam...

Page 243: ... Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 Instruments 39 Tachometer O BK Y Check Engine Lamp BK Y BK Y GY O Table 4 8 Wire Harness Connectors in Figure 4 24 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 39 Main harness to instruments 10 place Multilock und...

Page 244: ...N YES NO Check engine lamp function OK Check for trouble codes See 4 4 CHECKING FOR TROUBLE CODES With ignition key switch OFF reconnect black ECM connector 10 With ignition key switch ON verify that there is NOT a 4 second lamp OFF period Is there a lamp OFF period YES NO Repair short to ground on BK Y wire between connector 39 and connector 10 Repair short to ground on BK Y wire between connecto...

Page 245: ...r look for spark Repeat proce dure on other spark plug cable 1WARNING 1WARNING 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 removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could re...

Page 246: ...on Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker b0527x4x Fuel Pump Ignition Coil 83 BN Y BN Y GN W BK W R W Electronic Control Module ECM Connector 10 Connector 11 GY GY TN GN TN W TN W Clutch Switch 95 Side Stand Switch 60 Neutral Switch GY Cam Position Sensor 14 A B C GN W R W Y BE Y BE GY BE O BE O BK W C B A b0617x4x LTGN GY BK GY Bank Angle Sensor 134 ...

Page 247: ...econds and check engine lamp illuminate NO No pump response but light OK See 4 14 FUEL PRESSURE TEST NO Pump OK but no light See 4 10 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON YES Install Fuel Pressure Gauge See 4 14 FUEL PRES SURE TEST While cranking engine for more than two seconds to ensure proper system operation verify that pressure rises to 46 53 PSI 317 365 kPa Adequate pressure NO Incor...

Page 248: ...nce See 4 16 MISFIRE Check coil by substituting one known to be good OR Check coil resistance See 4 31 IGNITION COIL YES Connect Breakout Box Check continuity between ignition coil Terminal A of connec tor 83 and Breakout Box BK Pin 7 Measure resistance between ignition coil Terminal C and ECM Pin 6 10B Resistance should be less than 1 0 ohm Is it NO Disconnect cam position sensor connector 14 Wit...

Page 249: ...le CMP sensor and wires to identify any loose connects engine misfires or stalls Any found YES Pinion gear key failure loose rotor cup or other mechanical failure NO Replace cam position sensor See Section 7 NO Repair YES NO Disconnect connector 14 Measure resis tance between Terminal B and Connector 14B and Breakout Box GY Pin 3 Is resistance greater than 1 0 ohms Remove cam timer cover using 1 8...

Page 250: ...gh the side stand switch See Figure 4 29 By disengaging the clutch and grounding the relay through the clutch switch See Figure 4 30 If the ECM does not appear to be receiving power check the ground sources A blown ignition fuse can also disable the ECM DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 13 flow chart 1 Connect BREAKOUT BOX Pa...

Page 251: ... Handlebar Switch 22 TN W TN W Main Chassis Ground Diode 1 Diode 2 Neutral Switch Side Stand Switch 60 W BK W BK ECM 10 Pin 1 also provides power to fuel pump both fuel injectors coil and bank angle sensor Table 4 10 Wire Harness Connectors in Figure 4 31 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 22 Right handlebar switch 4 place under fuel cell right side 95 Clutch swi...

Page 252: ...en on GY O wire between ignition relay and fuse Check for 12 volts on ignition relay Terminal 30 GY O Voltage present Replace ignition relay See 7 5 STARTER INTERLOCK Check for 12 volts on ignition relay Terminal 86 W BK Voltage present Repair open on W BK wire between connector 22 and ignition relay YES Remove seat and check ignition fuse Is fuse OK YES Replace ECM See 4 29 ELECTRONIC CONTROL MOD...

Page 253: ...pilt fuel immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 3 See Figure 4 33 Attach FUEL PRESSURE GAUGE Part No HD 41182 to Schraeder valve on fuel supply fitting a Verify that fuel valve 2 and air bleed petcock 4 on the gauge are closed b See Figure 4 34 Remove protective cap...

Page 254: ...utions could result in death or serious injury 7 See Figure 4 34 Turn engine off Detach pressure gauge from Schraeder valve a Open the air bleed petcock to relieve fuel system pressure and purge the pressure gauge of gasoline b Remove pressure gauge from valve c Install protective cap on valve DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test ...

Page 255: ...gnition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY LowFuel Lamp GY BN Y BN Y Electronic Control Module ECM Connector 10 Connector 11 BK Y R O O Instruments 39 Fuel Pump GY 86B 86A Table 4 11 Wire Harness Connectors in Figure 4 36 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 39 Instruments 10 place Multilock under fuel cell 86 Fuel pump 4 place ...

Page 256: ...D on pump side of con nector 89 during first two seconds after key ON Is volt age greater than 1 VDC Check for restricted pump inlet screen Is screen restricted NO Move negative probe to GY wire on Terminal 87 of ignition relay Measure voltage during first two seconds after key ON Is voltage greater than 1 VDC YES Locate and repair poor connection between ignition relay and fuel pump NO Move negat...

Page 257: ...nal Probe BN Y wire at 86A during the first two seconds after key ON Does test lamp light YES NO Connect Breakout Box HD 42682 to ECM Check continuity between 86A Ter minal C BN Y wire and ECM connector 10 black Termi nal 3 Is continuity present Inspect fuel pump wiring Is wiring OK YES NO Repair fuel pump wiring NO Replace fuel pump assembly See 4 40 FUEL PUMP YES Locate and repair open on BN Y w...

Page 258: ...D CONTROL 4 15 ADJUSTMENTS See Figure 4 37 Use the adjuster attached to the throttle body to make idle speed adjustments Normal idle speed 850 1050 RPM Figure 4 37 Idle Adjustment Screw 1 6811 1 Idle Adjustment Screw Cable not Shown 2 Stop Plate 2 ...

Page 259: ...plug and igni tion coil For best results use a needle nose pliers for removal installation on coil Gently grasp cable as close to terminals as possible b Using an ohmmeter touch probes to terminals on each end plug wire c Compare resistance values to Table 4 12 Replace cables not meeting specifications Reinstall and repeat procedure on other spark plug cable 3 If carbon tracking is evident replace...

Page 260: ...der fuel cell 83 Coil 3 place Packard under fuel cell left side b0544x4x A B C F R Ignition Coil 83 Electronic Control Module ECM Connector 10 Connector 11 GY GY BE O BE O R R R GY R BK R GY R BK R BK R BK R BK GY O Ignition 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Int...

Page 261: ...heck for faulty plug wire connections and wire boots for carbon tracking Are wires OK YES Check for Faulty worn or cracked spark plug s Plug fouling due to engine mechanical fault Faulty or poor connection at plug NO Replace faulty wires YES Coils should be free of carbon tracking Are they NO Replace ignition coil YES Switch coil with unit known to be good Perform spark test Did spark jump gap dur...

Page 262: ...e between battery positive and coil connector 83 Terminal B W BK Wiggle harness Is resistance continuously less than 1 0 ohm YES Replace cam sensor with a unit known to be good Does problem still exist NO Find source of intermittent and repair YES Install original cam sensor Replace ECM See 4 29 ELECTRONIC CONTROL MODULE NO OK 5 6 7540 7541 7542 ...

Page 263: ...inals poor terminal to wire connection and damaged harness Perform 4 8 WIGGLE TEST to locate intermittents If connections and harness check out OK monitor TP sen sor voltage using a Scanalyzer or DVOM while moving related connectors and wiring harness If the failure is induced the TP sensor display will change TP sensor scaling Observe the TP sensor voltage dis play while opening the throttle with...

Page 264: ...ule ECM Connector 10 Connector 11 Cam Position Sensor R W 5 Volt Reference V Y TP Sensor Signal BK W Sensor Ground R W V Y GN W BK W A B C 14 BK W R W GN W Table 4 14 Wire Harness Connectors in Figure 4 42 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 14 Cam position sensor 3 place Deutsch near starter 88 TP sensor 3 place Packard behind air cleaner backplate ...

Page 265: ...flow chart Follow steps while wiggling harness and monitoring DVOM NO Replace TP sensor 4 36 THROTTLE POSI TION SENSOR Clear codes if Scanalyzer is available and road test did check engine lamp come on and set CODE 11 NO System now OK YES Install original TP sensor and replace ECM 4 29 ELECTRONIC CON TROL MODULE Road test again to verify YES Connect Breakout Box if not already connected Disconnect...

Page 266: ...Find short to ground on V Y wire NO Check continuity from Pin 2 of connector 11 to Terminal B on connector 88 Continuity present YES Locate and repair open in V Y wire NO Replace TP sensor See 4 36 THROTTLE POSITION SENSOR YES 7590 7580 7605 Locate and repair open in R W wire NO Check continuity between connector 88 Terminal B V Y wire and Pin 2 of connector 11 Continuity present YES 7615 Locate a...

Page 267: ...re Check for the following conditions Poor connection Inspect the ECM harness connector 11 fuel injector connectors 84 85 and O2 sensor con nector wiring for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Dirty stuck open injectors The motorcycle may run lean dirty clogged injectors or rich stuck open in...

Page 268: ...uit b0529x4x Oxygen Sensor 137 Electronic Control Module ECM Connector 10 Connector 11 V GY V GY 1 137B 137A Table 4 15 Wire Harness Connectors in Figure 4 45 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 137 Oxygen sensor 1 place above starter ...

Page 269: ...OM to Pin 4 and Pin 8 of connector 11 gray or use Scanalyzer Turn ignition ON and start engine Engine must be on and running for Scanalyzer to read O2 sensor values Observe O2 voltage Is it approximately 0 5 volts Install Breakout Box HD 42682 leaving harness side connector 11 disconnected from the Breakout Box Is the O2 voltage approximately 0 5 volts YES NO Inspect V GY wire for shorts to voltag...

Page 270: ...ignition OFF and reconnect O2 sensor Turn ignition ON and start engine Allow engine to reach operating temperature Does voltage quickly flunctuate between 0 4 0 6 volts NO YES Check for restricted fuel filter or fuel line Restriction present NO Check for air leaks at induction module Air leak present YES Replace fuel line or filter NO Fuel injectors may be dirty See Fuel Injectors Removal under 4 ...

Page 271: ...d set CODE 13 NO System now OK YES Install original O2 sensor and replace ECM 4 29 ELECTRONIC CONTROL MODULE Road test again to verify YES See Code 13 Test Part 2 of 3 for diagnostic material NO Continued from Code 13 Test Part 2 of 3 Turn ignition OFF and reconnect O2 sensor Turn ignition ON and start engine Allow engine to reach operating temperature Does voltage quickly flunctuate between 0 4 0...

Page 272: ...insulation Check the following conditions Poor connection Inspect ECM harness connector 11 for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Shifted sensor The temperature to resistance values table may be used to test the ET sensor at various tem perature levels in order to evaluate the possibility of ...

Page 273: ...Electronic Control Module ECM Connector 10 Connector 11 PK Y 1 Engine Temperature Sensor Location b0801x4x 90A 90B REAR CYLINDER Table 4 17 Wire Harness Connectors in Figure 4 46 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 90 Engine temperature sensor 1 place bullet above rear cylinder head left side ...

Page 274: ...GEN SENSOR YES Using a DVOM measure the resistance between Pin 9 of 11 and Pin 2 of 10 and Pin 11 of 10 on Breakout Box Is it greater than 1 0 megaohm NO Examine PK Y wire in harness for open circuit and repair YES NO Examine harness for short to ground and repair Clear codes and confirm proper operation with no check engine lamp At some point in the flow chart you may be instructed to jump direct...

Page 275: ...n and set only CODE 14 With ET sensor disconnected dis connect ECM connector 11 Mea sure resistance between ECM Pin 9 of 11 and Pin 2 of 10 Is resistance less than 1 ohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 9 of 11 and Pin 2 of 10 on Breakout Box Is the voltage 0 volts Install original ET sensor replace ECM 4 29 ELEC TRONIC CONTROL MODULE and...

Page 276: ...ss Perform 4 8 WIGGLE TEST to locate intermittents If connections and harness check out OK use the Scana lyzer to check intake air temperature reading while mov ing related connectors and wiring harness If the failure is induced the IAT sensor display will change Shifted sensor The temperature to resistance values table may be used to test the ET sensor at various tem perature levels in order to e...

Page 277: ... 10 Connector 11 Lt GN Y Intake Air Temperature Sensor 89 Lt GN Y 5 volt reference and sensor signal BK W sensor ground 1 2 BK W Lt GN Y IAT Sensor 7087 P89B P89A Table 4 19 Wire Harness Connectors in Figure 4 47 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 89 IAT sensor 2 place Deutsch behind air cleaner backplate ...

Page 278: ... OXYGEN SENSOR clear codes if Scana lyzer is available and road test Did check engine lamp come on and set only With IAT sensor disconnected dis connect ECM connector 11 Mea sure resistance between ECM Pin 10 of 11 and Pins 2 and 11 of 10 Is resistance less than 1 megaohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 10 of 11 and Pin 2 of 10 on Breako...

Page 279: ...e resistance between ECM Pins 10 and 7 of connector 11 on Breakout Box Is it greater than 1 0 megaohm NO Examine BK W wire in harness for open circuit and repair YES Using a DVOM measure the resistance between ECM Pin 10 of connector 11 on Breakout Box and ground Is it greater than 1 0 megaohm NO Examine Lt GN Y wire and BK W wire in harness for short between these two circuits and repair YES NO E...

Page 280: ...otes The reference numbers below correlate with the circled num bers on the Code 16 flow charts 1 The ECM is monitoring voltage at ECM connector 10 black Terminal 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX 2 This checks for voltage drops in the ECM power circuit If a significant voltage drop is not present condition may be caused by excessive starter current draw Scanalyze...

Page 281: ... R BK R GY R BK R BK R BK R BK GY O Ignition 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY GY Table 4 20 Wire Harness Connectors in Figure 4 50 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat ...

Page 282: ...Pin 1 of 10 on Breakout Box with key ON Is voltage drop greater than 0 5 volt System OK YES NO Check for excessive starter cur rent draw See 5 6 STARTER SYSTEM TESTING Measure voltage drop between Battery Positive Terminal and Terminal 87 on ECM safety interlock relay with key ON Is voltage drop greater than 0 5 volt NO Replace ignition relay 1 2 Clear codes and confirm proper operation with no ch...

Page 283: ... Terminal and silver post of 30 amp circuit breaker with key ON Is voltage drop greater than 0 5 volt YES NO Repair R wire or terminals Measure voltage drop between Battery Positive Terminal and copper post of 30 amp circuit breaker with key ON Is voltage drop greater than 0 5 volt YES NO Replace circuit breaker Replace BK wire between circuit breaker and battery 7781 YES Measure voltage drop betw...

Page 284: ...ly 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 removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 1 Purge fuel line and remove fuel tank See 4 37 FUEL TANK 2 Use HARNESS CONN...

Page 285: ... W Ignition relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit Electronic Control Module ECM Connector 10 Connector 11 GY b0543x4x 1 2 1 2 Rear Fuel Injector 85 Front Fuel Injector 84 W Y W Y GN GY GY GN GY GY GY Table 4 21 Wire Harness Connectors in Figure 4 53 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 84 Front injector 2 place under fuel cell 85 Rear...

Page 286: ...r connector 85 Is resistance less than 0 5 ohm YES Check for loose or corroded terminals in harness Repair as necessary Replace injector See 4 41 THROTTLE BODY AND INTAKE MANIFOLD YES NO NO Go to Code 23 32 Test Part 2 of 2 YES NO Repair open or poor connection Using Breakout Box check with test lamp between ECM 10 Pin 5 CODE 23 or ECM 10 Pin 8 CODE 32 and ECM 10 Pin 1 Does light flash when cranke...

Page 287: ...ector Is resistance less than 0 5 ohm With DVOM still attached perform 4 8 WIGGLE TEST to locate intermittents Repair as necessary Find and repair connection or open wire YES NO 1 With the engine off Scanalyzer Active Diagnostic Test Mode can be used to energize either the front or rear injector once each second for a total of five seconds 2 With the engine off Scanalyzer Active Diagnostic Test Mo...

Page 288: ...om the cam position sensors at which time it is reactivated DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 24 25 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 purple pin probes and patch cord 2 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX Scanalyzer Notes The Scanalyzer icon appears at those points in th...

Page 289: ...ion 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY Front Spark Plug Rear Spark Plug Y BE Y BE Table 4 22 Wire Harness Connectors in Figure 4 56 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 83 Ignition coil connector 3 place Packa...

Page 290: ...re resistance between ECM and coil terminals as follows Resistance should be less than 0 5 ohms Is it Trouble Code Coil Terminal ECM Terminal 24 Front C BE O 6 25 Rear A Y BE 7 NO Repair open wire or connection YES Perform 4 8 WIGGLE TEST Intermittents found NO YES Repair as necessary 2 2 1 1 With the engine off Scanalyzer Active Diagnostic Test Mode can be used to energize either the front or rea...

Page 291: ...otes The reference numbers below correlate with the circled num bers on the Code 33 flow chart 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 red pin probe and patch cord 3 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gray socket probe and patch cord Scanalyzer Notes The Scanalyzer icon appears at those points in the flow ch...

Page 292: ...gnition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY LowFuel Lamp GY BN Y Electronic Control Module ECM Connector 10 Connector 11 O O Instruments 39 GY BN Y BK Y R Fuel Pump 86B 86A Table 4 23 Wire Harness Connectors in Figure 4 59 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 39 Instruments 10 place Multilock under fuel cell 86 Fuel pump 4 place ...

Page 293: ... FUEL PUMP Clear codes if Scanalyzer is available and road test Did check engine lamp come on and set only CODE 33 YES NO Install original fuel pump 4 40 FUEL PUMP and replace ECM 4 29 ELECTRONIC CONTROL MODULE System OK Fuel pump on continuously YES Locate and repair short to ground on BN Y wire NO Check continuity of BN Y wire between 10 Pin 3 and Pin C of 86 Continuity present YES Repair open N...

Page 294: ...ly 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 removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 2 Purge fuel line and remove fuel tank to access instru ment connector 39 Se...

Page 295: ...sory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker Instruments 39 Tachometer PK PK To Starter Interlock Circuit O Electronic Control Module ECM Connector 10 Connector 11 Table 4 24 Wire Harness Connectors in Figure 4 62 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 39 Main harness to instruments 10 place Multilock under f...

Page 296: ...uity at Breakout Box between Pin 12 and Pin 11 in connector 10 Continuity present Locate and repair short on PK wire to ground YES Plug in 10 Connect voltmeter across Pin 12 and Pin 11 at Breakout Box 10 Start engine and let motor idle Is voltage approximately 4 0 6 0 volts NO Clear codes and confirm proper operation with no check engine lamp Reconnect 39 Locate intermittents using 4 8 WIGGLE TEST...

Page 297: ...ode occurs the engine may stop running The engine may still be restarted and ridden to the dealership for repair DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 44 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gray pin probes and patch cord 2 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX Figure 4 63 Bank A...

Page 298: ...Y Lt GN GY BK GY GY Lt GN GY BK GY GY R R R GY R BK R GY R BK R BK R BK R BK GY O Ignition 20A Memory 15A Spare 15A Lights 15A Instruments 15A Accessory 15A Ignition Switch 33 Engine Stop Switch 22 TN W Ignition Relay W BK GY O To Main Circuit Breaker To Starter Interlock Circuit GY GY 86 Table 4 25 Wire Harness Connectors in Figure 4 65 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch u...

Page 299: ...n Lt GY GN wire 4 0 6 0 volts Measure voltage between Socket C GY and Socket B BK Is voltage 11 13 volts 11 13 volts 0 volts Go to Code 44 Test Part 2 of 2 YES Is bank angle sensor correctly installed NO Repair open in GY wire between 134 and harness YES Are ferrous metals located within 0 25 in 6 4 mm of sides face or top of bank angle sensor NO Install properly See 4 34 BANK ANGLE SENSOR YES Ret...

Page 300: ...x BK Pin 10 Is continuity present NO Repair open in Lt GN GY wire YES Check continuity to ground for Socket B BK and connector 11 Pin 8 Is continuity present NO Repair open in ground wire YES Check continuity to ground for Socket A Lt GN GY and connector 134 Is continuity present NO Replace ECM See 4 29 ELECTRONIC CONTROL MODULE YES Repair short to ground on Lt GN GY wire Clear codes and confirm p...

Page 301: ...es indicate a failure which requires replacement of the ECM See 4 29 ELECTRONIC CONTROL MODULE Code 52 RAM failure Code 53 ROM failure Code 54 EE PROM failure Code 55 Microprocessor failure NOTE Dealership technicians filing warranty claims should use job time code 7913 for all Code 52 53 54 and 55 ECM replace ments ...

Page 302: ...y continue to run not run normally or stop running altogether DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 56 flow charts 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 7 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 black pin probes and patch cord 3 See 4 30 CAM POSITION SENSOR AND ROTOR Figure 4 66 Cam Position Se...

Page 303: ... W 5 volt reference GN W sensor signal BK W sensor ground Electronic Control Module ECM Connector 10 Connector 11 A B C R W V Y GN W BK W BK W GN W R W Table 4 26 Wire Harness Connectors in Figure 4 67 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 14 Cam position sensor 3 place Deutsch near starter 88 TP sensor 3 place Packard behind air cleaner backplate ...

Page 304: ...S NO Measure continuity between Pin A on 14 and Pin 1 on 11 Continuity present Disconnect harness side connector 11B GY from Breakout Box Measure voltage between Pin 1 and Pin 7 of connector 11 Voltage present NO Repair open in R W wire between connectors 11 and 14 NO Repair open in BK W wire between connectors 11 and 14 YES YES 12 volts Locate and repair R W wire short to voltage Locate and repai...

Page 305: ...r R W Perform 4 8 WIGGLE TEST and repair intermittent YES NO Repair Remove timing cover and cam position sensor Observe rotor cup while cranking engine Does rotor turn YES Check rotor for damage Is rotor loose or damaged NO Is rotor attached properly YES Remove gearcase cover and inspect for damage NO Repair YES Replace rotor and retest NO Replace cam position sensor and clear code Retest Prob lem...

Page 306: ...wo screws and washers 3 3 If installing a new ECM calibrate throttle position sensor using SCANALYZER Part No HD 41325 See 4 36 THROTTLE POSITION SENSOR 1WARNING 1WARNING 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 ...

Page 307: ... 3 Fuel pump output 4 Check engine lamp 5 Injector front output 6 Front coil primary 7 Rear coil primary 8 Injector rear output 9 No function 10 Bank angle sensor input 11 System ground B coil 12 Tachometer out Table 4 28 Pin Table for ECM Connector 11 Gray PIN FUNCTION 1 5 volt sensor power 2 Throttle position sensor 3 Camshaft position sensor 4 Oxygen sensor 5 No function 6 No function 7 Sensor ...

Page 308: ...position of each cam position sensor wiring termi nal in plug end of connector 6 See Figure 4 72 Remove connector terminal pins 16 See 7 25 DEUTSCH ELECTRICAL CONNECTORS 7 Remove timer cover a Drill off heads of outer timer cover pop rivets 1 using a 3 8 in 9 525 mm drill bit b Tap remaining rivet shafts inboard through holes in timer cover 2 and inner cover 4 c Remove timer cover Remove inner cov...

Page 309: ... 2 Timer Cover 3 Screw 2 4 Inner Cover 5 Timer Plate Stud 2 6 Bolt 7 Cam Position Sensor 8 Trigger Rotor 9 Seal 10 Gearcase Cover 11 Spark Plug 2 12 Ignition Coil 13 Front Spark Plug Cable 14 Rear Spark Plug Cable 15 Cable Strap 16 Terminal Pin 17 Cam Position Sensor Connector 14 18 Secondary Lock 19 Electronic Control Module ECM 20 Screw 2 20 ...

Page 310: ... ANGLE SENSOR 86 84 85 83 88 89 14 134 10 11 91 COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLOW LT LIGHT DIODE NO CONNECTION PIN CONNECTOR SOCKET CONNECTOR SPLICE CONNECTION CONNECTOR CODE TO GROUND FROM IGN RLY BK 1 2 BK TN GN R BE S1 95 CLUTCH SWITCH IGN MODULE FROM 2 GN BK W R IGN POWER BE 22 W BK W BK S8 1 3 2 4 GY O B R K R B R R K...

Page 311: ...igure 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 TIM...

Page 312: ...SULTS if resistance is not within nor mal operating range Test Results 1 A low resistance value indicates a short in the coil wind ing Replace coil 2 A high resistance value might indicate that there is some corrosion oxidation of the coil terminals Clean the termi nals and repeat resistance test If resistance is still high after cleaning terminals replace coil 3 An infinite ohms or no continuity ...

Page 313: ...r 7 83 5 Remove two screws and washers to drop coil from frame INSTALLATION 1 See Figure 4 77 Attach coil to frame with screws and washers Tighten to 4 6 ft lbs 5 8 Nm 2 See Figure 4 78 Attach connector 7 83 3 Connect front spark plug cable to connector 2 and rear spark plug cable to connector 1 4 Install left side scoop See 2 36 AIR SCOOP 1WARNING 1WARNING Always connect positive battery cable fi...

Page 314: ...ee Figure 4 79 Unplug 1 place connector 137 under battery tray 2 Remove oxygen sensor from exhaust header using a 22 mm or 7 8 in crow s foot or flare nut socket INSTALLATION 1 Apply LOCTITE ANTI SEIZE LUBRICANT to threads of sensor Make sure anti seize is marked as safe for use with O2 sensors 2 See Figure 4 79 Thread sensor into exhaust header Tighten sensor to 42 45 ft lbs 57 61 Nm 3 Connect 1 ...

Page 315: ...ine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 1 See Figure 4 81 Screw sensor into rear cylinder head with special ET sensor socket Make sure wire is in cut out portion slot of socket to prevent damage Tighten ET sensor to 10 14 ft lbs 14 19 Nm 2 Install rubber boot to ET Sensor wire push wire through hole in boot with smaller OD side towards sensor 3 Push ru...

Page 316: ...ition REMOVAL 1 See Figure 4 82 Locate bank angle sensor below left side of tail section Unplug sensor connector 134 2 Remove screw and washer to detach sensor from frame INSTALLATION 1 Position bank angle sensor on frame mounting tab Make sure locating post on sensor engages hole in mounting tab 2 Install bank angle sensor to mounting tab with screw and new locknut Tighten screw to 25 27 in lbs 2...

Page 317: ...nspect sensor grommet for damage and replace as required INSTALLATION 1 Install IAT sensor and grommet into snorkel 2 Connect IAT sensor connector 89 to sensor 3 Place a small piece of double sided tape at the upper center of the air filter foam gasket that fits against the backing plate 4 Position air filter on air cleaner backing plate 5 Install air cleaner cover a Position air cleaner cover ove...

Page 318: ... switch to IGNITION Turn the handlebar mounted Engine Stop Switch to the RUN posi tion but do not start the engine 6 Calibrate TP sensor using Scanalyzer Part No HD 41325 a From Diagnostic Menu press 7 to display Calibra tion Menu b Press 1 to activate TPS Zero Function c Press Enter to verify throttle plate is fully closed Scanalyzer will then calibrate sensor 7 Set idle speed a Press the mode ke...

Page 319: ...stalls press the starter button for 3 seconds to remove any remaining fuel from fuel line 2 See Figure 4 88 Remove seat fuel tank mount and fuel tank cover See 2 40 SEAT 3 Prop fuel tank against frame to gain access to fuel sup ply fitting Wrap a shop towel around the fuel supply fit ting 1WARNING 1WARNING A small amount of gasoline will drain from the fuel sup ply fitting and fuel line when remov...

Page 320: ... and top of fuel tank b See Figure 4 91 Tighten screws to 16 18 in lbs 1 8 2 0 Nm in the order shown 8 Install vent valve and fitting See 4 38 FUEL TANK VENT VALVE 9 Perform Fuel Tank Pressure Test CLEANING AND INSPECTION 1WARNING 1WARNING An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank Use extreme caution when servicing fuel tanks Gasoline...

Page 321: ...AT NOTE Use a good quality unleaded gasoline 91 pump octane or higher Octane rating is usually found on the pump 6 Fill fuel tank Turn ignition key ON and listen for fuel pump activation 7 Carefully inspect for leaks FUEL TANK PRESSURE TEST The fuel tank is a sealed pressure tested assembly when it leaves the factory If the fuel cap flange seal is broken the fuel tank must be pressure tested as li...

Page 322: ... use 4 See Figure 4 90 Cut cable tie holding vent hose to fitting and remove vent hose from fuel tank 5 While holding vent valve with angled needle nose pliers remove fitting from vent valve 6 Pull the vent valve from the gasket and remove from fuel tank INSTALLATION 1 Wipe inside and outside vent valve mounting hole to make sure there is no gasoline or excess Hylomar seal ant present 2 See Figure...

Page 323: ...n specified torque range loosen fitting rotate vent valve and try again Repeat as required to get proper align ment of nozzle within specified torque range 8 See Figure 4 90 Attach vent hose to nozzle on fitting with new cable tie 9 Fill fuel tank with proper fuel 91 Octane and install gas cap 10 Connect negative battery cable Tighten battery terminal hardware to 60 96 in lbs 7 11 Nm 11 Pressurize...

Page 324: ...tremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 4 See Figure 4 94 Remove hose clamps from both sides to detach filter 5 Position new filter in bracket with arrow pointing in direc tion of fuel flow Install two cable ties around filter and bracket NOTE If bracket was removed for any reason tighten bolt to 30 33 ft lbs 41 45 Nm 1WARNING 1W...

Page 325: ...nd rubber seal 6 6 Push electrical and fuel fitting studs back into tank 7 Reach inside fuel filler cap hole and remove pump assembly REPAIR Fuel Pump Replacement 1 Remove fuel pump assembly from tank 2 See Figure 4 96 Remove retaining clamp 5 from pump body 4 using a pair of cutters 3 Pull pump outlet fitting from pump holder housing 2 Detach electrical wires 3 and discard old pump 4 Place new ru...

Page 326: ...f piece of wire approximately 24 in 61 cm long b Attach pump electrical connector to wire c Feed wire into tank through fuel filler cap hole and out through electrical fitting hole smaller hole in bottom of tank Gently pull on wire to seat pump 3 Install pump assembly inside tank through fuel filler cap hole Position pump assembly with filter facing motorcy cle license plate When properly aligned ...

Page 327: ...ressure gas before removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 1 Purge fuel line and remove fuel tank See 4 37 FUEL TANK 2 Remove air cleaner cover and backplate See 4 42 AIR CLEANER 3 See Figure 4 100 On California models pull EVAP hose from fitting 3 Figure 4 100 Throttle Body and Intake Manifold 1 ...

Page 328: ...ve intake flanges 14 from manifold Remove and discard seals 15 REPAIR Throttle Position Sensor See 4 36 THROTTLE POSITION SENSOR for removal installation and calibration procedures Fuel Injectors Removal 1 Remove throttle body and intake manifold See 4 41 THROTTLE BODY AND INTAKE MANIFOLD 2 See Figure 4 102 Separate fuel rail assembly 3 from throttle body manifold a Remove both injector clips 4 b ...

Page 329: ...ke flanges onto manifold with the counterbore facing out Each intake flange is labeled and the pieces are not inter changeable 2 Place a new seal in each intake flange with the beveled side against the counterbore 3 See Figure 4 105 Attach both throttle cables Add free play to cables if necessary a With the throttle body close to the right side of the bike but not fully installed place idle contro...

Page 330: ... c Make sure throttle body is centered between cylin ders and tighten all intake flange screws to 6 10 ft lbs 8 14 Nm 6 Attach wiring a Injector cables are tagged F ront and R ear for ease of assembly Push connector halves together until latches click Grooves in female connector must align with the tabs in male housing b Connect throttle position sensor by pushing the con nector halves together Sl...

Page 331: ...ith breather bolts 23 to cylinder heads Tighten breather bolts to 10 15 ft lbs 14 20 Nm 3 Install air cleaner backing plate 21 a Insert intake air temperature sensor plug 29 through air cleaner backing plate 21 from back side of air cleaner backing plate b Position breather hoses 15 19 on breather bolts 23 4 Install but do not tighten three screws 17 and washers 18 to secure air cleaner backing pl...

Page 332: ... Gasket 2 11 IAT Sensor 12 IAT Grommet 13 Breather Hose Snorkel 14 Gasket 15 Breather Hose 16 Breather Tee 17 Screw 3 18 Washer 3 19 Breather Hose 20 Grommet 21 Backing Plate 22 Bolt 23 Bolt Breather 2 24 Support Plate 25 Wellnut 3 26 Clamp 3 27 Screw 28 Gasket 29 IAT Connector 89 and Wiring 4 2 3 1 3 2 6 7 8 9 10 20 22 2 21 11 23 5 14 28 26 10 24 23 25 2 27 12 13 15 17 18 16 19 29 b0665x4x ...

Page 333: ...ster vent hose These vapors pass through the throt tle body manifold and are burned as part of normal com bustion in the engine The large diameter canister to air cleaner backplate hose canister fresh air inlet hose supplies the canister with fresh air from the air cleaner TROUBLESHOOTING 1WARNING 1WARNING Verify that the evaporative emissions system hoses do not contact hot exhaust or engine part...

Page 334: ...h mounting plate 2 from clamps 1 5 Remove countersunk screws and locknuts 5 to sepa rate bracket 4 from mounting plate 2 INSTALLATION Vent Valve 1WARNING 1WARNING Verify that the fuel tank vent hose does not contact hot exhaust or engine parts The hose contains flammable vapors that can be ignited if damaged which could result in death or serious injury 1 Install vent valve See 4 38 FUEL TANK VENT...

Page 335: ...ct to and that hose clamps are properly tightened and positioned on straight section of fitting and not on the fitting barb Failure to comply may result in fuel leakage which could result in death or seri ous injury NOTE The barb is the larger outside diameter portion bump on the fuel fitting 2 Connect fuel tank vent hose 1 and canister vent hose 2 to the carbon canister Canister vent hose attache...

Page 336: ...4 118 2002 Buell X1 Fuel System HOME NOTES ...

Page 337: ...Electric Starter System 5 2 5 3 Starting System Diagnosis 5 5 5 4 Starter Activation Circuits 5 7 5 5 Diagnostics Troubleshooting 5 8 5 6 Starter System Testing 5 11 5 7 Starter 5 12 5 8 Starter Solenoid 5 19 Table Of Contents ELECTRIC STARTER 5 ...

Page 338: ......

Page 339: ... 400 amp max 2 4 V Stall Torque 8 ft lbs 11 Nm min 2 4 V SERVICE WEAR LIMITS IN MM Brush Length minimum 0 433 11 0 Commutator Diameter minimum 1 141 28 981 ITEM TORQUE NOTES Battery Terminal Hardware 60 96 in lbs 7 11 Nm page 5 18 Starter Battery Positive Cable Nut 60 85 in lbs 7 10 Nm metric page 5 18 Starter Mounting Bolts 13 20 ft lbs 18 27 Nm page 5 18 ...

Page 340: ...tarter relay is activated and battery current flows into the pull in winding 10 and the hold in winding 11 to ground The magnetic forces of the pull in and hold in windings in the solenoid push the plunger 7 causing it to shift to the left This action engages the pinion gear 1 with the clutch ring gear 13 At the same time the main solenoid contacts 8 are closed so battery current flows directly th...

Page 341: ...ing circuit see wiring diagram Starting circuit see wiring diagram 1 Pinion Gear 2 Idler Gear 3 Field Winding 4 Armature 5 Brush 6 Ball Bearing 7 Solenoid Plunger 8 Main Solenoid Contacts 9 Battery 10 Pull in Winding 11 Hold in Winding 12 Overrunning Clutch 13 Clutch Ring Gear Starter at moment starter switch is closed Starter during cranking ...

Page 342: ... windings Ball bearing sticks Check brush spring tension Correct on lathe or replace Correct by undercutting Replace Replace Replace Replace Repair or replace lead wire Replace bearing 2 Pinion does not engage with ring gear while starter is running or engine cannot be cranked Battery Voltage drop due to discharged battery Short circuited or open between elec trodes Poor contact condition of batte...

Page 343: ...y Voltage Present With Starter Button Pressed Check for Ground at Relay Terminal 85 Ground Present Inspect Starter Interlock Circuit or Correct Relay Ground Check for Battery Voltage to Starter Button W BK Wire Battery Voltage Present Replace Right Handlebar Switchgear NO Repair Wiring to Starter Button YES YES Repair Wiring From Starter Button to Relay NO YES YES NO NO 1 Perform Voltage Drop Test...

Page 344: ...est Are Test Results in Range Perform Starter Motor Current Draw Test on Vehicle STARTER STALLS OR SPINS TOO SLOWLY Disconnect Solenoid Relay Terminal from Solenoid Is 12V Present at GN Wire Terminal with Starter Button NOT Pressed Is 12V Present on Starter Relay Terminal 86 with Starter Button NOT Pressed Replace Right Handlebar Switchgear Replace Starter Relay Replace Solenoid YES NO NO YES NO N...

Page 345: ...50A 20A 20A 0 1A 150A 0 1A 150A 20A 20A 0 1A 150A 0 1A 150A 20A 20A 0 1A 150A 0 1A VDC ITEM A IDEAL CLOSED CIRCUIT GROUND CIRCUIT OPEN CIRCUIT b0157x5x OV VDC VDC 12V OV ITEM B ITEM C ITEM D 1 1 Start Switch 2 Relay 3 Solenoid 4 Starter 5 Battery 6 Main Circuit Breaker 7 Ignition Switch 8 Ignition Circuit Breaker 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 1 2 4 3 5 6 7 8 ...

Page 346: ...g all the voltage dropped and the entire difference in potential displayed on the meter 6 Typically a good circuit will drop less than 1 volt 7 If the voltage drop is greater back track through the con nections until the source of the potential difference is found The benefit of doing it this way is speed a Readings aren t as sensitive to real battery voltage b Readings show the actual voltage dro...

Page 347: ... R BK TN GN DIODE 1 DIODE 2 62 TN FUSE BLOCK IGNITION 15A 15A 15A ACCESSORY LIGHTS 15A INSTRUMENTS 61 MEMORY SPARE 20A 15A 15A SPARE 20A 15A SPARE SPARE B R K R B R R K R B R K R GY KEY SWITCH OFF P IGN A B C D 33 S7 BATTERY BK GN BK R MASTER CIRCUIT BK MAIN CHASSIS GROUND TN SWITCH NEUTRAL COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLO...

Page 348: ...5 10 2002 Buell X1 Electric Starter HOME NOTES ...

Page 349: ...R CURRENT DRAW TEST Starter Current Draw Test NOTE Engine temperature should be stable and at room tem perature Battery should be fully charged See Figure 5 8 Check starter current draw with an induction ammeter before disconnecting battery Proceed as follows 1 Verify that transmission is in neutral Disconnect spark plug wires from spark plug terminals 2 Clamp induction ammeter over positive batte...

Page 350: ...lace starter in vise using a clean shop towel to prevent scratches or other damage 2 See Figure 5 11 Attach one heavy jumper cable 6 gauge minimum a To the starter mounting flange 1 b To the negative terminal of a fully charged bat tery 3 Connect a second heavy jumper cable 6 gauge mini mum a To the positive terminal of the battery 2 b To an inductive ammeter 3 Continue on to the bat tery terminal...

Page 351: ...See Figure 5 13 With test leads still connected in the manner specified in the previous SOLENOID PULL IN TEST disconnect solenoid motor terminal battery negative test lead B at negative battery post only reconnect loose end of this test lead to positive bat tery post instead 2 Observe starter pinion a If starter pinion remains in pull in position solenoid is working properly b If starter pinion do...

Page 352: ...ter is less than 1 141 in 28 981 mm c Check armature bearings Replace if necessary CAUTION Do not use sandpaper or emery cloth to remove burrs on commutator Otherwise abrasive grit may remain on commutator segments this could lead to excessive brush wear Use only the recommended crocus cloth 8 Check depth of mica on commutator If undercut is less than 0 008 in 0 203 mm use an undercutting machine ...

Page 353: ...ester a Touch one probe to any commutator segment 1 b Touch the other probe to the armature core 2 c There should be no continuity infinite ohms If there is continuity then the armature is grounded Replace grounded armatures Figure 5 18 Undercutting Mica Separators Mica must not be left with a thin edge next to segments RIGHT WAY Mica Undercutting mica with piece of hacksaw blade WRONG WAY Startin...

Page 354: ...st be replaced 13 See Figure 5 23 Check for OPEN FIELD COILS with an ohmmeter or continuity tester a Touch one probe to the field wire 1 b Touch the other probe to each of the brushes attached to the field coil s 2 c There should be continuity 0 ohms If there is no continuity at either brush then the field coil s are open and the field frame must be replaced 14 See Figure 5 24 Test BRUSH HOLDER IN...

Page 355: ...ing 10 to solenoid housing 11 use new O ring 16 Be sure to install return spring 17 and ball 18 Figure 5 25 Starter Drive Assembly 4 O Ring 5 Drive Housing 6 Screws 1 Drive 2 Idler Gear 3 Idler Gear Bearing 1 2 3 4 5 6017 6 Figure 5 26 Starter Assembly 1 Thru Bolt 2 2 End Cover Screw and O Ring 2 3 End Cover 4 Brush Holder 5 Brush Spring 4 6 Armature 7 Field Frame 8 Armature Bearing 2 9 Drive Hous...

Page 356: ...e 4 b Attach circuit breaker wire ring terminal 3 c Attach positive battery cable ring terminal 2 d Install nut with washer 1 metric Tighten to 60 85 in lbs 7 10 Nm e Replace protective boot if present 3 See Figure 5 9 Install both starter mounting bolts and washers Tighten to 13 20 ft lbs 18 27 Nm 4 Install primary cover See PRIMARY COVER under 6 2 PRIMARY CHAIN 5 Fill transmission to proper leve...

Page 357: ...nd a hollow cylinder con taining a movable plunger DISASSEMBLY 1 See Figure 5 27 Remove screws 1 and clip 2 2 Remove cover 3 and gasket 4 Discard gasket 3 Remove plunger 5 from solenoid housing 6 ASSEMBLY 1 See Figure 5 27 Replace wire connection hardware as necessary 2 Install plunger 5 in solenoid housing 6 3 Install new gasket 4 onto cover 3 4 Position cover with gasket onto solenoid housing In...

Page 358: ...5 20 2002 Buell X1 Electric Starter HOME NOTES ...

Page 359: ... Clutch 6 10 6 6 Transmission 6 17 6 7 Transmission Case 6 19 6 8 Shifter Forks and Drum 6 21 6 9 Mainshaft and Countershaft 6 24 6 10 Main Drive Gear 6 30 6 11 Access Door Bearings 6 32 6 12 Right Transmission Case Bearings 6 33 6 13 Transmission Installation and Shifter Pawl Adjustment 6 34 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 360: ......

Page 361: ...Capacity 1 0 quart 0 95 liter Fluid Part No quart 98854 96 Fluid Part No gallon 98855 96 TRANSMISSION GEAR RATIOS FINAL OVERALL First Low Gear 2 69 9 717 Second Gear 1 85 6 687 Third Gear 1 43 5 180 Fourth Gear 1 18 4 269 Fifth High Gear 1 00 3 615 PRIMARY DRIVE ENGINE TO TRANSMISSION Engine Sprocket 35 teeth Clutch Sprocket 56 teeth Ratio 1 60 1 FINAL DRIVE TRANSMISSION TO REAR WHEEL Transmission...

Page 362: ...4 Nm on interior of chaincase page 6 4 Primary Chain Inspection Cover Screws 40 60 in lbs 5 7 Nm page 6 3 Primary Cover Mounting Screws 100 120 in lbs 11 14 Nm 3 lengths page 6 5 Large primary cover screws 16 28 ft lbs 22 38 Nm page 6 5 Shifter Lever Mounting Bolt 27 29 ft lbs 37 39 Nm LOCTITE THREADLOCKER 243 blue page 6 5 Shifter Shaft Assembly Locknuts top and bottom 90 110 in lbs 10 12 Nm tigh...

Page 363: ...ary chain REMOVAL Primary Cover 1WARNING 1WARNING To protect against 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 Disconnect negative cable from battery terminal 2 Raise rear wheel off floor using REAR WHEEL SUP PORT STAND Part No B 41174 3 Remove muffler See 2 28 EXHAUST S...

Page 364: ...ary cover 1 2 Remove locknut 2 from chain adjuster screw 3 Turn adjuster screw out of threaded boss in primary cover 3 Slide shoe 6 off plate 5 shoe must be slid off plate toward closed or blind side of shoe Remove locknut 4 and plate 5 INSTALLATION Primary Chain Adjuster 1 See Figure 6 3 If shoe 6 is badly worn replace it or adjust assembly 2 Install plate 5 over top of chain adjuster screw 3 Pla...

Page 365: ...lubricant See 1 10 CLUTCH 8 Adjust clutch See 1 10 CLUTCH 9 Adjust primary chain tension See 1 13 PRIMARY CHAIN 10 See Figure Figure 6 5 Apply LOCTITE THREAD LOCKER 243 Blue to shift lever mounting bolt 11 Install shifter lever assembly with mounting bolt washer and plastic bushings and spacer Do not tighten mount ing bolt 12 Install rubber washer and upper shift lever assembly to splined shaft 13...

Page 366: ...ER 6 Remove rear fender See 2 32 REAR FENDER 7 See Figure 6 6 Remove rear wheel a Remove rear axle nut 1 metric lockwasher 2 washer 3 and right side axle carrier 4 b Hold axle adjuster bolt 5 with a 5 16 in wrench Loosen locknut 6 and axle adjusters 7 Repeat on left side c From left side slowly pull rear axle from swingarm As axle is removed remove right side spacer rear brake caliper mount left s...

Page 367: ...ng adjusting bolt e Tighten isolator TORX bolt to 63 70 ft lbs 85 95 Nm f See Figure 6 9 After tightening TORX isolator bolt verify that seam on isolator is perpendicular to swin garm mount block 3 Install rear fender See 2 32 REAR FENDER 4 Align the new belt and rear wheel See 1 11 DRIVE BELT DEFLECTION 5 Install sprocket cover See 2 30 SPROCKET COVER 6 See Figure 6 7 Install sideplate and right ...

Page 368: ...rd Unscrew nut 5 from end of adjusting screw 6 Remove hook of ramp from cable end coupling 16 Remove cable end 10 from slot in coupling 7 Remove and discard retaining ring 13 from ramp assembly to separate inner and outer halves Remove three balls 7 from ramp sockets CLEANING AND INSPECTION 1 Thoroughly clean all parts in cleaning solvent 2 See Figure 6 10 Inspect three balls 7 of release mech ani...

Page 369: ...ng inward place hook of ramp around coupling button c Rotate assembly counterclockwise until tang on inner ramp fits in slot of primary cover 6 3 Secure assembly in place a Thread wellnut 2 on adjusting screw 3 until slot of screw is accessible with a screwdriver b Fit nut hex into recess of outer ramp 1 c Turn adjusting screw counterclockwise until resis tance is felt 4 Adjust clutch release mech...

Page 370: ...rom the engine will be transmitted to the rear wheel When the clutch is disengaged clutch lever pulled to left han dlebar grip the pressure plate 6 is pulled outward by clutch cable action against the diaphragm spring 7 thereby compressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch plates 1 2 and 3 together The fiber plates 3 are now fr...

Page 371: ...tall bearing 3 and washer 4 d Thread the tool handle 5 onto end of forcing screw CAUTION See Figure 6 15 Turn compressing tool handle 5 only the amount required to release spring seat 9 and remove snap ring 8 Excessive compression of dia phragm spring 6 could damage clutch pressure plate 7 4 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw 1 flats to prevent the f...

Page 372: ... Spring Seat 11 Diaphragm Spring 12 Retaining Ring 13 Release Plate 14 Retaining Ring 15 Bearing 16 Adjusting Screw 17 Pressure Plate 18 Fiber Plate 8 19 Steel Plate 6 20 Spring Plate 21 Mainshaft Nut 22 Washer 23 Clutch Hub 24 Retaining Ring 25 Bearing 26 Clutch Shell 27 Retaining Ring b0009c6x 27 26 25 24 23 22 21 20 19 18 17 16 15 14 1 2 3 5 6 7 9 10 11 12 13 8 4 Labeled OUT ...

Page 373: ...ew assembly into pressure plate a See Figure 6 18 Align two tabs on perimeter of release plate with corresponding recesses in pres sure plate b See Figure 6 17 Secure the adjusting screw assembly with large retaining ring 1 8 Attach tools to compress clutch diaphragm spring See Step 2 of CLUTCH PACK under 6 5 PRIMARY DRIVE CLUTCH 9 Remove clutch pack components See Steps 3 4 of CLUTCH PACK under 6...

Page 374: ...hat are damaged or are warped more than 0 006 in 0 152 mm 2 Check the diaphragm spring 11 for cracks or bent tabs Install a new spring if either condition exists 3 See Figure 6 19 Check fiber plates for thickness a Wipe the lubricant from the eight fiber plates and stack them on top of each other b Measure the thickness of the eight stacked fiber plates with a dial caliper or micrometer The mini m...

Page 375: ... ring positioned against outboard side of spring seat and fully seated in groove of clutch hub carefully loosen and remove compression tool Primary Drive 1 See Figure 6 22 Assemble clutch hub and shell if nec essary a Press new bearing 3 in clutch shell 4 Secure bearing with a new retaining ring 2 b Press inboard end of clutch hub 1 into shell bear ing 3 Secure with new retaining ring 5 on end of ...

Page 376: ...ged 3 Install mainshaft nut and washer a Apply two or three drops of LOCTITE THREAD LOCKER 262 red onto threads on end of main shaft b Place washer 2 on mainshaft with the word out facing away from clutch hub 3 c Install nut 1 left hand threads Tighten to 70 80 ft lbs 95 109 Nm 4 Remove SPROCKET LOCKING LINK 5 Install adjusting screw assembly into pressure plate a See Figure 6 18 Align two tabs on...

Page 377: ...hich transmits the force through a gear shifter shaft The shifter shaft actuates a pawl and a shifter fork drum The shifter fork drum moves shifter forks which slide a series of shifter clutch gears on the mainshaft and countershaft into and out of mesh with the other gears LUBRICATION Drain transmission and refill to correct level with fresh clean lubricant at least once each year or every 5000 m...

Page 378: ... 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 Neutral Power Flow Sliding Member Countershaft Mainshaft Out 1st Gear Countershaft Mainshaft In 2nd Gear Countershaft Mainshaft In 3rd Gear Countershaft Mainshaft Out In 5th Gear Countershaft Mainshaft Out In 4th Gear Countershaft Mainshaft In Out XLH transpower flow ...

Page 379: ...l number of turns counterclockwise d Move rear wheel as far forward as possible 6 See Figure 6 28 Place transmission in first gear Remove two socket head screws 5 and lockplate 4 CAUTION Transmission sprocket nut has left hand threads To pre vent damage turn nut clockwise to loosen and remove from main drive gear shaft 7 Remove transmission sprocket nut 3 from main drive gear shaft 1 8 Remove seco...

Page 380: ...ON Thoroughly clean transmission compartment with cleaning solvent Blow parts dry with compressed air Inspect parts to determine if any must be replaced Replace all parts that are badly worn or damaged Neutral Indicator Switch See Figure 6 31 The neutral indicator switch is threaded into the transmission portion of the right crankcase half See 7 22 NEUTRAL INDICATOR SWITCH for testing removal and ...

Page 381: ...neutral indicator pin prevents removal in the other direction 6 Remove shifter forks 1 2 and 3 CLEANING AND INSPECTION 1 See Figure 6 32 Clean all parts except bearings 19 20 with solvent Figure 6 32 Shifter Mechanism 1 Shifter Fork 3rd and 5th Gear 2 Shifter Fork 1st and 2nd Gear 3 Shifter Fork 4th Gear 4 Cotter Pin 3 5 Shifter Fork Pin 3 6 Neutral indicator Pin 7 Shifter Fork Drum 8 Shifter Drum...

Page 382: ...hrough the shifter forks as shown in Figure 6 33 This will prevent possible damage to the cotter pins 4 See Figure 6 32 Secure shifter mechanism a Lubricate the three shifter fork pins 5 with SPORT TRANS FLUID b Drop fork pins 5 through the holes in shifter forks c With a small screwdriver press on the pins while manipulating the forks back and forth until the pin seats in the drum groove d Secure...

Page 383: ...2002 Buell X1 Drive Transmission 6 23 HOME Figure 6 35 Detent Roller Arm 3557 Countershaft Bearing Detent Roller Arm Detent Plate Typical ...

Page 384: ...ertain wear pattern and a kind of set with its mating parts For this rea son it is important that each component be reinstalled in its original location and facing its original direction 3 See Figure 6 37 As each component is removed place it on a clean surface in the exact order of removal See Figure 6 38 Using RETAINING RING PLIERS Part No J 5586 remove and discard retaining ring 5 next to count...

Page 385: ...ter shaft 14 Sprocket Belt 15 Seal Oil 16 Spacer Belt Drive 17 Ring Quad 18 Ring Retaining 19 Bearing Ball 20 Bearing Needle 21 Gear Mainshaft 5th 22 Gear Mainshaft 2nd 23 Gear Mainshaft 3rd 24 Gear Mainshaft 1st 25 Gear Mainshaft 4th 26 Spacer 27 Mainshaft 28 Bearing 29 Ring Retaining 30 Seal 31 Retention Collar 32 TORX Screw 33 Ring Retaining 34 Nut Mainshaft 35 Washer Spring 36 Bushing 14 b0129...

Page 386: ...nd retaining ring 5 which is next to mainshaft 1st gear 24 and slide off end of shaft 7 See Figure 6 41 Place COUNTERSHAFT GEAR SUP PORT PLATE Part No HD 37404 under countershaft 4th gear 4 Place assembly on press with suitable metal blocks under the support plate Place a socket or mandrel smaller than inside diameter of bearing and press countershaft free of access cover Slide mainshaft 1st gear ...

Page 387: ...e gears Replace the gears if dogs are rounded cracked battered chipped or dimpled 4 Discard all retaining rings that were removed ASSEMBLY CAUTION During assembly the split bearings 7 and the internal bores of the gears must be lubricated with SPORT TRANS FLUID prior to assembly Leaving these parts dry could accelerate wear at start up and may result in vehi cle damage 1 Find a section of pipe tha...

Page 388: ...ext to washer 6 6 Locate countershaft first gear 8 Gear 8 has a radial groove at one side of the gear Install gear 8 over split bearing 7 with radial groove facing access door 7 Install thrust washer 6 and retaining ring 5 next to gear 8 8 Locate countershaft 4th gear 4 This flat shoulderless gear is splined and has a single radial groove at one side Position gear next to retaining ring 5 Place be...

Page 389: ...aring 7 16 Install mainshaft 2nd gear 22 onto shaft The shifter fork groove must face the access door 17 Install shouldered countershaft 5th gear 12 The single radial groove must face away from the access door 18 Expand retaining ring 5 and slide into groove next to countershaft 5th gear 12 19 See Figure 6 50 At outside of access door position retention collar 31 next to end of countershaft with b...

Page 390: ...he gear is pressed out against the resistance of the bearing inner race Without any support at the inner race the bearing is destroyed Whenever the main drive gear is removed the main drive gear bearing will also have to be replaced 5 At outside of case place driver 4 and thrust washer 5 over end of bolt 2 Install and tighten nut 6 until 5th gear 3 is free Figure 6 51 Main Drive Gear Assembly 1 Ma...

Page 391: ...c Press in the inner bearing to a depth of 0 080 in 2 032 mm INSTALLATION 1 Replace main drive gear bearing See 6 10 MAIN DRIVE GEAR 2 See Figure 6 55 Use MAIN DRIVE GEAR REMOVER AND INSTALLER TOOL for assembly a Take bolt 2 and place washer 5 followed by main drive gear 4 over end of bolt b From inside of case insert bolt and main drive gear through inner race of ball bearing c Insert threaded en...

Page 392: ...d 2 Lay bearing squarely over bore with printed side of bear ing upward Place section of pipe or tubing slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder 3 Install new retaining ring with beveled side facing away from bearing Shift Drum Bushing 1 Lay access door on press with outside surface of door downward 2 See Fi...

Page 393: ...g in groove inside bearing bore with beveled side facing outside of case 4 Lubricate bearing with SPORT TRANS FLUID Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in diameter 2 From the outside of the case place the needle bearing open end first next to the bearing bore Hold the driver squarely against the closed end of the bearing and tap the bearing into place The...

Page 394: ...g 9 using SHIFT DRUM RETAINING RING INSTALLER Part No HD 39151 d Verify that retaining ring is fully engaged with drum groove 6 See Figure 6 61 Align shifter shaft a Place transmission in third gear b Place a No 32 drill bit 0 116 in dia through hole in detent plate 3 and between pawl 2 and drive pin at end of shifter drum shaft c Push down top of crank 4 to remove all clearance between pawl and d...

Page 395: ...t nut an additional 30 40 d See Figure 6 62 Install lockplate 4 over nut 3 so that two of lockplate s four drilled holes diagonally opposite align with sprocket s 2 two tapped holes NOTE The lockplate has four screw holes and can be turned to either side so you should be able to find a position without having to additionally tighten the nut If you cannot align the screw holes properly the nut may ...

Page 396: ... the original screws may be reused up to three times After the third removal installation cycle replace both screws with new screws identical to the original 14 Install the remaining removed components in the reverse order of the removal procedures See the procedures listed in the respective component sections 15 Adjust drive belt tension See 1 11 DRIVE BELT DEFLECTION 16 Fill transmission to prop...

Page 397: ... 12 Tail Lamp 7 33 7 13 Turn Signals 7 34 7 14 Turn Signal Flasher 7 36 7 15 Handlebar Switches 7 37 7 16 Speedometer Sensor 7 40 7 17 Speedometer 7 41 7 18 Tachometer 7 43 7 19 Speedometer Performance Check 7 45 7 20 Tachometer Performance Check 7 50 7 21 Horn 7 51 7 22 Neutral Indicator Switch 7 53 7 23 Fuses and Circuit Breakers 7 54 7 24 Electrical Connectors 7 55 7 25 Deutsch Electrical Conne...

Page 398: ......

Page 399: ...5 Instrument Fuse 15 Odometer Fuse 15 BULB CHART BULBS REQUIRED WATTS AMPS PART NUMBER Headlamp High Low replaceable bulb 1 60 55 5 0 4 58 67969 96Y Position Lamp European models only 1 4 0 33 67968 96Y Marker Lamps Tail Stop Lamp 1 5 21 0 42 1 75 68075 94Y Turn Signal Lamp front and rear 1 bulb each 4 2 0 0 17 68968 99Y Indicator Lamps on Instrument Support High Beam Indicator 1 2 1 0 15 68024 94...

Page 400: ...ws right side 12 17 in lbs 1 2 Nm longer screw on bottom page 7 38 Headlamp Housing Screws 6 8 ft lbs 8 11 Nm metric page 7 32 Neutral Indicator Switch 3 5 ft lbs 4 7 Nm LOCTITE THREADLOCKER 243 blue page 7 53 Rotor Mounting Bolts 90 110 in lbs 10 12 Nm LOCTITE THREADLOCKER 243 blue page 7 22 Spark Plugs 11 18 ft lbs 15 24 Nm page 7 1 Stator TORX Mounting Screws 30 40 in lbs 3 4 Nm T 27 TORX with ...

Page 401: ...e and the engine speed The ET sensor provides the ECM the current engine temper ature Proper fuel and spark delivery are dependent on the temperature of the engine The ECM will provide a richer fuel mixture on start up and a higher degree of spark advance As the vehicle warms up to operating temperature the fuel mix ture will lean and the spark advance will decrease The information provided by the...

Page 402: ...Rivet 2 2 Timer Cover 3 Screw 2 4 Inner Cover 5 Timer Plate Stud 2 6 Bolt 7 Cam Position Sensor CMP 8 Trigger Rotor 9 Seal 10 Gearcase Cover 11 Spark Plug 2 12 Ignition Coil 13 Front Spark Plug Cable 14 Rear Spark Plug Cable 15 Cable Strap 16 Terminal Pin 17 CMP Connector 14 18 Secondary Lock 19 Ignition Module 20 Washer 2 21 Screw 2 21 20 ...

Page 403: ...activated See Table 7 2 REMOVAL 1WARNING 1WARNING To protect against accidental start up of vehicle discon nect the negative battery cable before proceeding Inade quate safety precautions could result in death or serious injury 1WARNING 1WARNING Always disconnect the negative battery cable first If the positive battery cable should contact ground with the negative cable installed the resulting spa...

Page 404: ... with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 4 Install battery cables positive cable first 1WARNING 1WARNING 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 igni...

Page 405: ... cable will damage the cable s carbon core Disconnect spark plug cables from ignition coil and spark plug terminals Inspect all removed cables for damage INSPECTION 1 Inspect spark plug cables Replace cables that are worn or damaged a Check for cracks or loose terminals b Check for loose fit on ignition coil and spark plugs 2 Check cable boots caps for cracks or tears Replace boots caps that are w...

Page 406: ... the neutral switch By disengaging the clutch and grounding through the clutch lever switch Note that the ignition circuit allows operation in gear with the side stand extended if the clutch is disengaged However if the motorcycle is in gear with the side stand extended and the clutch is released the ignition ground is lost and the igni tion system is turned off This system will prevent vehicle op...

Page 407: ...shown in Figure 7 5 2 Check diode polarity as shown in Figure 7 6 Figure 7 5 Ohmmeter Diode Test Figure 7 6 Diode Polarity Continuity Infinite ohms b0643x4x b0644x4x TN TN GN Diode 1 Polarity TN GN TN W Diode 2 Polarity Figure 7 7 Diode Wiring TN W TN W Relay Block Diode 1 Diode 2 TN Neutral Switch TN TN GN To Clutch Switch 95 To Clutch Switch 95 TN GN Ignition Relay b0648x4x b0645x4x ...

Page 408: ...nd connector 60 Ground present Check for ground on BK wire of connector 60 Ground present YES Replace sidestand switch NO NO 5053 5054 5055 YES Repair open on TN GN wire YES Check Diode 1 with ohmmeter Diode OK Remove sprocket cover Check for ground at neutral switch terminal Ground present Check for ground on TN GN wire of Diode 1 Ground present Check for ground at TN wire on Diode 1 Ground prese...

Page 409: ... present Check for ground on TN W wire of Diode 2 Ground present Check for ground on TN GN wire of Diode 2 Ground present YES Check Diode 2 with ohmmeter Diode OK YES Diode installed backwards Reverse polarity Replace diode YES Repair open on TN GN wire between connector 95 and Diode 2 NO Replace clutch switch Check for ground on BK wire of connector 95 Ground present NO NO NO Repair open on BK wi...

Page 410: ...SENSOR 86 84 85 83 88 89 14 134 10 11 91 COLOR CODE BE BLUE BK BLACK BN BROWN GN GREEN GY GRAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLOW LT LIGHT DIODE NO CONNECTION PIN CONNECTOR SOCKET CONNECTOR SPLICE CONNECTION CONNECTOR CODE TO GROUND FROM IGN RLY BK 1 2 BK TN GN R BE S1 95 CLUTCH SWITCH IGN MODULE FROM 2 GN BK W R IGN POWER BE 22 W BK W BK S8 1 3 2 4 GY O B R K R B R R K R B R ...

Page 411: ...clutch switch attaches to the clutch con trol lever bracket The switch completes a path to ground for the ignition relay and the starter relay when the clutch is dis engaged Test the switch as follows 1 Unplug the 2 place clutch switch connector 95 2 Test the switch using an ohmmeter a With clutch engaged 1 switch open the switch should show ohms infinite ohms b With clutch disengaged 2 switch clo...

Page 412: ...seat and locate diodes within relay block 2 2 Test diodes using Starter Test flow charts under DIAG NOSTICS 3 Identify the diode which must be replaced Replace both diodes if necessary 4 Replace the diodes by pulling them straight out The spare diode may be used in either circuit as long as it is installed in the correct direction Main Circuit Breaker Attached to the frame above the battery the ma...

Page 413: ... to charge or does not charge at a satisfactory rate make the following recommended checks Battery Check for a weak or dead battery See 7 10 BATTERY Bat tery must be fully charged in order to perform any electrical tests Wiring Check for corroded or loose connections in the charging cir cuit See Figure 7 16 Voltage Regulator Inspection See Figure 7 13 The voltage regulator base must have a clean t...

Page 414: ...ST Record measurement and compare with TOTAL CURRENT DRAW TEST before proceeding Inspect rotor Replace stator Perform AC OUTPUT TEST Replace regulator Perform VOLTAGE OUTPUT TEST Damaged or slipping rotor Perform CURRENT OUTPUT TEST System tests good up to this point Suspect 1 Accessories on for long periods when vehicle is parked and not running 2 Accessories on when vehicle is ridden very slowly...

Page 415: ...7 16 Charging System Circuit 30A BK BK BK S2 BK RD RD BK BK b0749chr Master circuit breaker Main chassis ground Starter 30A BK BK BK S2 BK RD RD BK BK b0749chr Main Circuit Breaker Main Chassis Ground Starter Battery Stator Voltage Regulator 46 ...

Page 416: ...Any accessories must be considered and checked for excessive drain NOTE A battery with a surface discharge condition could suffer a static drain Correct by cleaning battery case Total Current Draw Test If battery runs down during use the current draw of the motorcycle components and accessories may exceed output of the charging system 1 See Figure 7 18 To check for this condition place load tester...

Page 417: ... voltage is higher regulator is not functioning prop erly or connections are loose or dirty Stator Check 1 Turn ignition key switch to OFF 2 See Figure 7 20 Connect an ohmmeter a Locate voltage regulator connector 46 near the oil pump Disconnect from alternator stator wiring b Insert one ohmmeter lead into either stator socket c Attach the other lead to a suitable ground 3 Test for continuity with...

Page 418: ...s c Run the engine at 2000 RPM The AC output should be 38 52 volts AC 2 Compare test results to specifications a If the output is below specifications charging prob lem could be a faulty rotor or stator b If output is good charging problem might be faulty regulator rectifier Replace as required 3 Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST on page 7 19 Figure 7 22 Che...

Page 419: ...Disconnect stator wiring 4 from volt age regulator wiring at connector 5 46 near the oil pump 2 Remove cable straps holding stator wire to oil filter hose 3 Withdraw stator wiring 4 from behind the gearcase cover 4 Remove and discard the four TORX screws 2 which secure stator 1 to left crankcase half CAUTION Stator TORX screws contain a thread locking compound Do not reuse existing screws Always u...

Page 420: ... the wiring 5 Connect alternator stator wiring to voltage regulator con nector 46 Bundle excess wiring in front of oil pump Secure bundle to oil filter hose using a new cable strap 6 See Figure 7 25 Attach rotor to sprocket a Position rotor on sprocket Align holes in sprocket with holes in rotor b Apply a drop of LOCTITE THREADLOCKER 243 blue to threads of each mounting bolt Insert the four mounti...

Page 421: ...om gold post of main circuit breaker c Route ground wire back to voltage regulator Cut and mark locations of cable ties while removing 5 Remove screws washers and voltage regulator from bracket 6 If necessary detach mounting bracket by removing screws washers and nuts INSTALLATION 1 See Figure 7 27 Attach new voltage regulator to bracket using two screws and washers Tighten screws to 9 11 ft lbs 1...

Page 422: ...rter nut Remove nut metric with washer to detach positive battery cable from starter INSTALLATION 1 Clean cable connectors and battery terminals using a wire brush or sandpaper to remove any oxidation 1WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which c...

Page 423: ...nut with washer metric Tighten nut to 60 85 in lbs 7 10 Nm b See Figure 7 29 Attach negative cable to frame below oil tank 4 Apply light coat of petroleum jelly or corrosion retardant material to both battery terminals Figure 7 30 Positive Battery Cable Protective Boot Not Shown 6590 1 1 Nut with Washer metric 2 Positive Battery Cable 2 ...

Page 424: ... be incorrect See BATTERY INSTALLA TION AND CONNECTION Load testing a discharged battery can also result in permanent battery damage 2 After charging allow battery to stand for at least one hour before testing 1WARNING 1WARNING Always turn the battery load tester OFF before connect ing the tester cables to the battery terminals Connecting tester cables with the load tester ON could cause a spark r...

Page 425: ...ble black from battery negative terminal 3 Unthread bolt and remove battery positive cable red from battery positive terminal 4 Remove battery strap locknut metric Unhook battery strap from frame near negative terminal 5 Cut cable strap holding oxygen sensor connector to bat tery 6 Remove battery from right side CLEANING AND INSPECTION 1 Battery top must be clean and dry Dirt and electrolyte on to...

Page 426: ...110 F 43 C during charging discontinue charging and allow the battery to cool Overheating may result in plate distortion internal shorting dryout or other damage 1 Perform a voltmeter test to determine the state of charge See BATTERY TESTING If battery needs to be charged proceed to step 2 CAUTION Always remove the battery from the motorcycle before charging Accidental electrolyte leakage will dam...

Page 427: ...f battery tray Place battery strap around top side of battery b Hook edge of strap into frame tab c Insert threaded shaft on strap through frame tab d Install battery strap locknut on threaded shaft Tighten to 40 in lbs 4 5 Nm 5 Apply light coat of petroleum jelly or corrosion retardant material to both battery terminals 6 Secure oxygen sensor connector to battery tray with new cable strap 6 Insta...

Page 428: ...ient temperature and the battery s state of charge Batteries discharge at a faster rate at higher ambient temperatures To reduce the self discharge rate store battery in a cool not freezing dry place See Fig ure 7 35 Charge the battery every month if stored at temperatures below 60 F 16 C Charge the battery more frequently if stored in a warm area above 60 F 16 C NOTE The H D Battery Tender Automa...

Page 429: ...s 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 2 Purge fuel line and remove fuel tank See 4 37 FUEL TANK 3 See Figure 7 38 Cut as many cable straps ...

Page 430: ...lash 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...

Page 431: ...jor concern for motorcyclists Fail ure to have proper tail lamp operation could result in death or serious injury 5 Check tail lamp for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Check for tail lamp illumination c Squeeze front brake hand lever Check for brake lamp illumination Release front brake hand lever d ...

Page 432: ...ullet connectors on turn signal wires as shown in Figure 7 42 4 Install and align headlamp See 7 11 HEADLAMP 1WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 5 Check turn signals for proper operation If operation fails reread procedu...

Page 433: ...proper turn signal operation could result in death or serious injury 4 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Activate left turn signals using switch on left handle bar Front and rear left turn signals must flash c Activate right turn signals using switch on left han dlebar Front and ...

Page 434: ... could result in death or serious injury 3 Install seat See 2 40 SEAT 1WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 4 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per f...

Page 435: ...ss Left Side 1 Remove three screws from handlebar switch 2 Separate switch housings and remove from handlebar 3 Remove seat See 2 40 SEAT 1WARNING 1WARNING 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 Gas...

Page 436: ...all handlebar switch operations before riding motorcycle Visibility is a major concern for motorcy clists Handlebar switches not operating properly could result in death or serious injury 7 Check handlebar switch for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Start motorcycle c Turn ignition key switch to OFF L...

Page 437: ...n for motorcy clists Handlebar switches not operating properly could result in death or serious injury 5 Check handlebar switch for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b Check headlamp LOW and HIGH beam settings c Set headlamp to LOW beam Press passing lamp switch Headlamp should flash HIGH beam for as lon...

Page 438: ...tall bolt 1 to attach speedometer sensor 2 to crankcase 2 Connect speedometer sensor connector 65 to wiring harness Figure 7 54 Speedometer Sensor 1 6991 2 1 Bolt 2 Speedometer Sensor Figure 7 55 Speedometer Sensor Wiring 2 3 4 O W 1 W O W BK BK 5 6 7 8 9 10 O O Y R Y R R PK PK BK Y BK Y BK BK BK LT BE W W A B C BK W GY BK W R R Speedometer b0670x2x Tachometer Odometer Reset Button Speedometer Sen...

Page 439: ...difficulty during reassembly 5 Slide speedometer cover 6 away from speedometer a See Figure 7 58 Remove wires from speedometer one at a time After removing each wire reinstall screw immediately b Pull lamp 5 from bore 6 Pull speedometer and attached odometer reset button from front of dash panel 7 Remove mounting gasket if necessary 1WARNING 1WARNING The gasoline in the fuel supply line downstream...

Page 440: ...panel a Feed wires through opening in speedometer cover b Slide speedometer into rubber mounting gasket c See Figure 7 58 Insert lamp 5 d Attach wires to speedometer as shown 5 See Figure 7 57 Install speedometer cover 6 a Place speedometer cover over speedometer Align posts on back of speedometer with holes in cover Drain hole must be at the bottom of cover b Apply LOCTITE THREADLOCKER 243 blue t...

Page 441: ...achometer a Remove three lamps 1 2 and 3 and attached wires b Loosen screws and remove wires 4 5 and 6 one at a time After removing each wire reinstall screw immediately 6 Pull tachometer from front of dash panel 7 Remove rubber mounting gasket if necessary 1WARNING 1WARNING The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrol...

Page 442: ... into their appropriate bores d Attach wires 4 5 and 6 to tachometer as shown 4 See Figure 7 62 Install tachometer cover 5 a Place tachometer cover over tachometer Align posts on back of tachometer with holes in tachome ter cover Drain hole must be at the bottom of cover b Apply LOCTITE THREADLOCKER 243 blue to both nuts metric 3 c Fasten cover 5 to tachometer using two nuts met ric 3 and lockwash...

Page 443: ...osis or repair It can also assist in determining if speedometer replacement is necessary Speedometer Operation Test 1 See Figure 7 65 Locate the 3 place speedometer con nector 65 under the battery tray and disconnect Attach speedometer tester connector 2 Place speedometer tester power switch in the ON posi tion Place signal switch in the OUT position 3 Turn vehicle ignition switch ON 4 Begin test ...

Page 444: ...eedometer is inoperative but backlighting and odom eter work the speedometer sensor may not be working See Figure 7 66 Fabricate a test harness using the following parts This harness can also be used to test the tachometer Two Deutsch 3 place socket housings Part No 72113 94BK and six socket terminals Part No 72191 94 Deutsch 3 place pin housing Part No 72103 94BK and three pin terminals Part No 7...

Page 445: ... and verify operation Does display toggle between trip and odometer modes YES Verify trip display consists of correct numbers Are correct numbers displayed NO Replace speedometer YES Go to Speedometer Test Chart 2A NO Remove boot over trip reset switch Toggle trip reset switch without boot Does display toggle between modes YES Unit OK Return to customer NO Place jump wire across leads to reset swi...

Page 446: ...ed on speedometer while moving shaking vehicle harness connections Output erratic YES Repair as necessary NO Replace speedometer NO Bad connection found Repair con nector or harness DIAGNOSTIC NOTES Low battery voltage on speedometer tester may cause inaccurate test results Make sure speedometer tester battery is fully charged If necessary remove speedometer sensor and check for accumulation of de...

Page 447: ...for open wires Wires OK YES Replace speedometer NO Repair wires YES Check speedometer power O W wire and ground terminal BK wire voltage at back of speedometer Test voltage why shaking harness Does voltage flunctuate NO 4 6 VDC is not present Replace speedometer NO 4 6 VDC is present but no flunctuation to 0 1 VDC Replace speedometer sensor YES Repair as necessary NO Check for spark plug wire term...

Page 448: ...s nee dle to the desired RPM b Test the tachometer at several different RPM read ings to verify proper operation NOTE All tachometer accuracy tolerances were taken at 68 77 F 20 25 C Sweep Test 1 See Figure 7 67 Connect the speedometer tester to the cam position sensor Deutsch socket housing 2 Place speedometer tester power switch in the ON posi tion Place signal switch in the OUT position 3 Turn ...

Page 449: ...ower wire and BK ground wire to terminal clips on back side of horn 2 See Figure 7 68 Attach horn 3 to frame using bolt 1 and washer 2 3 Check horn operation If horn does not sound or fails to function satisfactorily see TROUBLESHOOTING a Turn ignition key switch to IGN b Press horn switch to activate horn c Turn ignition key switch to OFF 4 Install air scoop See 2 36 AIR SCOOP 5 Install fuel tank...

Page 450: ...K power and BK ground wires from terminal clips b Connect voltmeter positive lead to Y BK wire c Connect voltmeter negative lead to ground d Turn ignition key switch to IGN 3 See Figure 7 70 Depress horn switch and observe volt meter reading a If battery voltage is present horn or horn grounding is faulty If horn is faulty replace unit as an assem bly The horn is not repairable b If battery voltag...

Page 451: ...ition key switch is turned to OFF 2 Remove sprocket cover See 2 30 SPROCKET COVER 3 See Figure 7 71 Place transmission in first gear Remove two socket head screws 7 and lockplate 6 CAUTION Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft Transmission sprocket nut will be damaged if turned counterclockwise to remove 4 Remove transmis...

Page 452: ...both battery cables negative cable first 1WARNING 1WARNING 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 removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or ser...

Page 453: ...hind headlamp 39 Speedometer and Tachometer 10 place connector Under fuel tank on frame tube 46 Voltage Regulator Stator 2 place barrel Right side lower by oil pump 60 Side Stand Switch 2 place Amp Multilock Above left side rear isolator 61 Four 15 Amp Fuses odometer instruments lights and accessories and One 20 Amp Fuse ignition 5 slot fuse block Under seat in trunk left side 65 Speed Sensor 3 pl...

Page 454: ...ove within the socket housing and holds the terminal latches tightly closed NOTE The conical secondary locking wedge of the 3 pin con nector must be installed with the arrow pointing toward the external latch See Figure 7 75 If the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The lock indicates when te...

Page 455: ... tails 4 Strip lead removing 5 32 in 4 0 mm of insulation Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locki...

Page 456: ... pin terminal Figure 7 80 a With the flat edge against the terminal insert the pick Snap On TT600 3 into the cavity until it stops b Pivot the end of the pick away from the terminal to release the tang c Gently tug on wire to pull terminal from chamber Do not tug on the wire until the tang is released or the terminal will be difficult to remove A click is heard if the tang is engaged but then inad...

Page 457: ...he button always being the top of the connector 1 From the secondary lock side of the connector insert the terminal into its respective numbered chamber until it snaps in place For proper fit the slot in the terminal must face the tang in the chamber a If installing socket terminals see Figure 7 79 b If installing pin terminals see Figure 7 80 2 Gently tug on wire end to verify that the terminal i...

Page 458: ...of insulation Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact 6 See Figure 7 81 ...

Page 459: ...O GY O TN W TN W GN TN GN GY TN W BK 1 2 SIDESTAND SWITCH BK W R BK TN GN TN SWITCH NEUTRAL R Y O W GN Y R Y R Y O W BK S2 S6 TO STOPLIGHT S8 ACC POWER BRAKE SWITCH 1 2 1 3 2 4 O W O W R Y R Y LOW BEAM LIGHT POWER HORN HIGH BEAM FROM FLASHER LEFT TURN HORN POWER S5 BE Y O W BN V BN Y BK W 1 3 5 6 7 8 9 RIGHT TURN W BN BK GN BE 2 O L BE GY S9 S4 W BK Y 2 3 4 O W 1 BN K B V HIGH BEAM LOW BEAM LMP GR...

Page 460: ... TN W TN W GN TN GN GY TN W BK 1 2 SIDESTAND SWITCH BK W R BK TN GN TN SWITCH NEUTRAL R Y O W GN Y R Y R Y O W BK S2 S6 TO STOPLIGHT S8 ACC POWER BRAKE SWITCH 1 2 1 3 2 4 O W O W R Y R Y LOW BEAM LIGHT POWER HORN HIGH BEAM FROM FLASHER LEFT TURN HORN POWER S5 BE Y O W BN V BN Y BK W 1 3 5 6 7 8 9 RIGHT TURN W BN BK GN BE 2 O L BE GY S9 S4 W BK Y 2 3 4 O W 1 BN K B V HIGH BEAM LOW BEAM LMP GROUND P...

Page 461: ...APPENDICES SUBJECT PAGE NO Appendix A Tools A 1 Appendix B Metric Conversions B 1 Table Of Contents ...

Page 462: ......

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