Buell S1 Lightning 1996 Manual page 75

REAR BRAKE LINE AND SWITCH
REMOVAL
1. Open bleeder nipple cap on rear caliper. Install end of a
length of plastic tubing over caliper bleeder valve, while
placing free end in a suitable container. Open bleeder
valve (metric) about 1/2-turn. Pump rear brake pedal to
drain brake fluid.
2. See Figure 2-27. Remove banjo bolt (metric) and two
gaskets to detach brake line from rear brake caliper. Dis-
card gaskets.
3. See Figure 2-28. Remove banjo bolt (metric) and two
gaskets to detach brake line from rear master cylinder.
Discard gaskets.
4. See Figure 2-29. Remove screw and clamp to detach
brake line clamp from frame.
5. Remove brake line from clamp under oil tank.
6. Pull terminal sockets from spade connections at top of
brake lamp switch. Unthread switch from tee nut.
INSTALLATION
1. See Figure 2-29. Coat brake lamp switch threads with
LOCTITE PIPE SEALANT WITH TEFLON. Thread brake
lamp switch to tee nut of brake line. Tighten switch
assembly to 7-8 ft-lbs (9.5-10.8 Nm). Install terminal
sockets on switch spade connections.
2. From left side of vehicle, feed new brake line from rear
brake caliper mount forward to frame mount. Thread
brake line right to rear master cylinder.
3. Install screw and clamp to secure rear brake line to frame.
Tighten clamp screw to 10-12 ft-lbs (13.6-16.2 Nm).
4. Attach brake line to clamp under oil tank.
5. See Figure 2-28. Position new gaskets on each side of
master cylinder banjo fitting. Insert banjo bolt (metric)
through gaskets and banjo fitting. Thread bolt into master
cylinder and tighten to 10-12 ft-lbs (13.6-16.2 Nm).
6. See Figure 2-27. Position new gaskets on each side of
caliper banjo fitting. Insert banjo bolt (metric) through
gaskets and banjo fitting into caliper. Tighten banjo bolt
to 9.5-12.5 ft-lbs (12.9-17.0 Nm). Install bleeder valve if
removed. Refill master cylinder and bleed brakes. See
BRAKES in Section 1.
7. Tighten bleeder valve (metric) to 6-9 ft-lbs (8.1-12.2 Nm).
Install bleeder cap.
8. Test brake lamp operation with the rear brake pedal
applied and the ignition/headlamp switch turned to IGN.
www.PlanDeGraissage.org
5560
Banjo bolt
(metric)
Figure 2-27. Rear Brake Caliper Banjo Bolt
5521
Banjo bolt
(metric)
Figure 2-28. Rear Master Cylinder Banjo Bolt
5559
Clamp
Figure 2-29. Brake Line and Switch
Bleeder valve
(metric)
Brake lamp
switch
2-27