Xb9sXBUELLXb9sX's - 2000 Buell X1 Lightning Build Thread

[Xb9sXBUELLXb9sX]

Well, after trading in my Buell XB9SX three years ago and regretting it... I finally picked up another Buell. I ended up trading in my 2015 Yamaha WR250f straight across for a 2000 Buell X1 Lightning with 3000 original miles!!! After reading through the BuellXB and X1files sites, I decided to begin going through the bike, updating and upgrading along the way. First off, the bike when I picked it up.

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[Cooter]

Congrats on the new ride!!

[Xb9sXBUELLXb9sX]

Being that I love Buells for their "Around Engine" design, I had to remove the left cowl and lower cowl. Just to showcase that sportster engine.

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[Xb9sXBUELLXb9sX]

My first concern through my research was the primary chain tensioner recall. Apparently the original tensioner will fail, taking out most the the primary and transmission, and that not something I want to risk. I also noticed the exhaust mounts were not updated so I figured the tensioner was not upgraded either. The clutch cable casing was also dry-rotted, so I figured I replace it during the upgrade.

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First I purchased the upgraded tensioner from Hammer Performance, Motion Pro Clutch cable and a new primary gasket set.

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And my assumption was correct...

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[Xb9sXBUELLXb9sX]

Through cleaning the primary cover, I noticed the primary chain wasn't tensioned properly at some point throughout its life. Luckily the damage isn't bad and the cover appears structurally sound.

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The internals appeared to be in good shape.

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Installed the new tensioner, Amsoil 20W-50 primary fluid, clutch cable and sealed her up.

https://farm5.staticflickr.com/4628/38949627815_542fc7e023_z.jpg (https://flic.kr/p/22kR2na)

[Xb9sXBUELLXb9sX]

Next task was to update the exhaust mounts. This task was two-fold. The old style mounts are prone to cause exhaust bracket failure, and the Vance and Hines SSR2 exhaust is known to rattle itself apart... Which was obvious when I disassembled the exhaust...

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Noticed there was a crack in the elbow caused by the old style mounts

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When this happens, it puts undo stress on the header, causing the header itself to crack... A common area is near the rear cylinder O2 Port.

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So its off to be welded and repaired.

[Xb9sXBUELLXb9sX]

Lucky the header came off easily, without a broken exhaust stud. And the studs came out easily with some Aero Kroil.

***Seriously, If you ever have to remove the header nuts or studs (or any rusty/old fastners), spray them with Aero Kroil a couple times throughout the day before removal. When I removed them, they almost didn't feel tight...***

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Proof they came out in one peice. Rusty and All.

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Removed the exhaust gaskets and cleaned up the ports.

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[Xb9sXBUELLXb9sX]

While I'm waiting on parts for the exhaust, I upgraded the pegs.

Original

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Upgraded

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[Outlaw]

Good looking bike. Congrats on a good find.

[Cooter]

You are so right about the Aero-kroil:up:

I'd never spent time on a tuber before, but I rode about 2800 miles this summer all over the NW from S Dakota, Montana, Idaho, Washington, Canada, Oregon... On an M2 with a 1250 kit, 6-speed, Carb upgrade, and XB wheels, brakes, and front suspension swap. WOW, that bike really impressed me. They just do everything so well and comfortably:angel:



Someone replaced your beer in the garage with a water!?!? Oh NOOOOO!!!!:upset:

[Xb9sXBUELLXb9sX]

I agree! This bike has really impressed me with the little riding I've done with it. Compared to my XB9SX, this bike has a "raw" and simple feel to it that makes it much more fun to ride.

And you may have spotted the water, but you missed that it was still sealed... I had to be drinking something... Just sayin! ;)

Had a friend of mine weld up the crack for me in exchange for a case of Mountain Dew [I think it was a win-win]. Repair turned out great. Now I have to decide what I'm going to replace the Vance and Hines exhaust with...

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[Cooter]

Couldn't agree more. My preconceived notions of trusting a 20 year old bastard (sorry/true) bike and the resulting joy and trust it earned from me were a large part of the trips success.
There is no denying they are top notch capable and fun, to this day. Thats a feat thats very impressive in itself! While everybody scrambles for the last HP point, latest greatest computer wizardry, or whiz bang features... the tubers have their cult following for a very legitimate reason. #Respect




Don't worry, I drink water too! Lol. Just a sip. Right after sipping something else from the backwoods of Tennessee (or Kentucky):very_drunk:
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[bsd]

Did you remove the rivet plate on the clutch and replace with another clutch plate? Primary/Trans gets hammered when they come part. What about the ecm?

[Xb9sXBUELLXb9sX]

Did you remove the rivet plate on the clutch and replace with another clutch plate? Primary/Trans gets hammered when they come part. What about the ecm?

I did not, I honestly do not know about this. Can you fill me in?

Is there anything else I need to look out for in the primary? Only want to go back in there once...

And it does have a Race ECM on it.

[bsd]

The stock clutch has 8 fiber and 6 steel plates with the rivet plate in the middle. The upgrade kit eliminates the rivet plate and has more plates to make up space. The stock pressure plate is fine. No need of a 15% or more pressure plate on a lightly modded motor. Your clutch hand will thank you. The left side air scoop that is missing on your bike really helps cool down the rear cylinder too. And you have a very nice looking bike. I have two 99 X1 and like them alot. The word (raw) is exactly how I describe them compared to the newer XB bikes.

[Xb9sXBUELLXb9sX]

Well, with some advice in the previous posts, I decided to take the primary cover back off and replace the clutch with an extra plate clutch kit from Energy One Performance. Though the mileage on this engine is much less than the typical failure point on the grenade plate [I found anywhere between 10000mi up to 18000mi based on my search] I figured I'd take care of this before anything comes close to happening. This kit came with the clutch tool. With this upgrade I decided to buy the updated front exhaust mount hanger [which happened to be new in box], clutch circlip, circlip seat, and new primary chain tensioner sealing nut.

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[Xb9sXBUELLXb9sX]

The clutch came out easy with the supplied clutch tool.

https://farm5.staticflickr.com/4751/28433643669_44eb281b6a_k.jpg (https://flic.kr/p/KjzRDF)

[Xb9sXBUELLXb9sX]

And the clutch plates and spring plate, as well as the basket, looked great. It could have lasted quite a while longer, but replacement is cheap insurance.

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[Xb9sXBUELLXb9sX]

It all installed easily and I opted for the 15% stronger diaphragm spring because I like a stiff clutch.

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[Xb9sXBUELLXb9sX]

Buttoned it all back up and filled with Harley Davidson Primary Oil, as recommended by Energy One. Even opted for some chrome case bolts for a little extra bling.

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[Xb9sXBUELLXb9sX]

Next, I replaced the old front exhaust mount with the updated wishbone style mount. Much Beefier!!!

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[Xb9sXBUELLXb9sX]

Even replaced the old Z-Bracket!

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[Xb9sXBUELLXb9sX]

And I got bored, so I decided to polish up the headers a bit. Not bad 18 years of tarnish and an hours worth of work.

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[Silverrider]

They look New again!

[bsd]

Forgot to mention that the steel oil pump gear is known to fail. Both of my X1 now have the bronze oil pump gear in them. No rush for you to do it now, but sometime down the road.

[d_adams]

Looking good, waiting on the next update pics...

[Xb9sXBUELLXb9sX]

Looks like Dean was alluding to something...

Well, I finally picked out an exhaust and decided to go with the best! I ordered a Dean Adams Designs Tuber exhaust.

This thing is very well built, looks great and sounds even better. A little on the louder side, but that isn't a bad thing, one bit. Fit was great, much better then most exhaust systems I've installed. Dean is an outstanding guy btw. He called to confirm my order, gave me updates on the construction [with pictures], and even called me to make sure everything installed smoothly. Would definitely recommend his stuff to anyone.

During the install, I did find that when the header was welded up, it did warped a bit. Didn't notice at first and kinda crushed/messed up the front exhaust gasket. I smoothed it out a bit and it seemed to have sealed nicely. Passed the soapy water test anyways. On to the pictures.

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[Xb9sXBUELLXb9sX]

Here's how she sits for now. I've updated everything that needed to be fixed immediately, and she's back on the road. Needs a couple more small updates such as the oil pump gear and a new rear shock, but I'll be waiting a bit before I tackle these items. I have big plans for this bike, but I want to spend some time riding and enjoying it first. Will be giving any and all updates to this bike as I complete them.

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[Outlaw]

I like it. Nice bike.

[Xb9sXBUELLXb9sX]

Thought I'd jump back on here and give an update. I was cleaning the X1 a while ago, and noticed that when the previous owner installed the forcewinder intake, they removed the intake bracket. So I purchased a replacement to install.

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[Xb9sXBUELLXb9sX]

But, nothing can ever be that simple...

Without the bracket installed, the throttle body rotated downward quite a bit. To installed the intake bracket, I had to rotate it back up. When I started it back up and went for a ride, it was blatantly obvious the the install broke the seal on the intake seals. So I had to take off the entire intake...

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[Xb9sXBUELLXb9sX]

I figured since I was removing the entire intake track, I'd replace all the seals and even purchased a new fuel rail. This included new james gaskets "blue" intake seals, air cleaner gaskets, manifold and throttle body seals, and injector o-rings. Basically every seal/o-ring between the air filter and the heads. Even replaced the fuel line and fuel filter

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[Xb9sXBUELLXb9sX]

But of course, it still can't be that easy...

When I removed the intake manifold, I noticed a lot of epoxy and J-B weld. That kind of stuff really bothers me so I removed some of it to inspect the manifold. I discovered a large crack on the throttle body side, going all the way through the manifold.

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[Xb9sXBUELLXb9sX]

I ended up finding a decent intake manifold on eBay to replace the cracked manifold. Has a couple small dents on the injector inlets, but they are purely cosmetic and do not effect the seals on the injectors.

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[Xb9sXBUELLXb9sX]

With basically a brand new intake track, I put everything back together. Ran great, even better than before!

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[Xb9sXBUELLXb9sX]

And ever since I've had the bike, I hated how the head breathers were routed. The setup caused a small amount of oil, overtime, to drip through the filter and onto the engine/exhaust. So I added a catch can.

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[rb70383]

Surfing old threads. Bike looks great. Any new news?

[tenshots1]

catch can looks awesome!

[Cooter]

Great job:eagerness: Looks like a really nice X-1! and you have all the worms back in the can now...Haha

[_buelligan_]

Pretty nice clean up job on that X1, cool catch can install

[EliB]

First of all - as a new X1 owner - your posts have helped A LOT. So thank you. Please keep us updated on any other improvements.

Real quick - what pegs did you get? I do like those...

[34nineteen]

Those are old "Millenium edition" pegs. I think they are long since discontinued.

If you want more X1 info, go to thex1files.com