Buell 2002 P3 Service Manual page 104

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CLEANING AND INSPECTION
11 1
WARNING
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 could result in improper brake operation
which could result in death or serious injury.
1. Thoroughly clean master cylinder and all brake system
components. Stand master cylinder on wooden block or
towel to protect seating surfaces.
a. Examine walls of master cylinder reservoir for
scratches and grooves. Replace if damaged.
b. Verify that vent holes on master cylinder are com-
pletely open and free of dirt or debris.
2. Inspect boot on front of master cylinder for cuts, tears or
general deterioration. Replace if necessary.
ASSEMBLY
1. See Figure 2-46. Insert piston assembly (4), spring first,
into master cylinder.
2. Place round side of rod assembly (3) over piston.
Depress piston into master cylinder body (1) and secure
with a new snap ring (2).
3. Tuck rubber boot on rod assembly (3) into master cylin-
der body (1).
INSTALLATION
1. See Figure 2-45. 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 reservoir hose to master cylinder with clamp
(if removed).
2. See Figure 2-44. Apply LOCTITE THREADLOCKER 243
(blue) to both screws. Attach master cylinder (3) to frame
with spacers between master cylinder and footrest sup-
port. Tighten to 4-6 ft-lbs (5-8 Nm).
11 1
WARNING
Use only new black banjo washers (See Parts Catalog for
Part No.) with D.O.T. 4 brake fluid. Earlier silver banjo
washers are not compatible with D.O.T. 4 fluid and will
not seal properly over time. Failure to comply may
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
CAUTION
To avoid leakage after assembly, verify that banjo wash-
ers, banjo bolt, hydraulic brake line and bore of master
cylinder are completely clean.
3. See Figure 2-43. Connect brake line (3) to master cylin-
der (4) with two new banjo washers (2) and banjo bolt (1)
(metric). Tighten to 16-20 ft-lbs (22-27 Nm).
WARNING
WARNING
7704
1
3
3
1. Banjo Bolt (metric)
2. Screw (2) (metric)
3. Spacers
4. Rubber Boot
5. Rod Adjuster
6. Locknut
7. Clevis
Figure 2-44. Master Cylinder Mounting
4. Install push rod by screwing push rod into clevis.
NOTE
Brake pedal height should be set so top surface of brake
pedal is even with the top surface of the foot peg.
5. See Figure 2-44. Set brake pedal height.
a. Loosen locknut (6).
b. Turn rod adjuster (5) to obtain correct position.
c. Tighten locknut (6).
11 1
WARNING
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 and
death or serious injury
6. Add brake fluid and bleed brake system. See
Brakes.
7. 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.
2
2
4
5
6
7
WARNING
Bleeding
2002 Buell P3: Chassis 2-29