Front Brake Master Cylinder - Buell 2002 X1 Handbook

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FRONT BRAKE MASTER CYLINDER

REMOVAL
NOTE
Do not remove the master cylinder unless problems are being
experienced.
1. See Figure 2-21. Drain brake fluid into a suitable con-
tainer. Discard of used fluid according to local laws.
a. Open bleeder valve (metric) about 1/2-turn.
b. Install a length of plastic tubing over caliper bleeder
valve. Place free end in a suitable container.
c. Pump brake hand lever to drain brake fluid.
d. Tighten bleeder valve to 3-5 ft-lbs (4-7 Nm)
2. Remove mirror from right handlebar.
CAUTION
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
3. See Figure 2-22. Remove banjo bolt (6) (metric) and two
banjo washers (4) to disconnect brake line (5) from mas-
ter cylinder. Discard banjo washers.
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 pivot.
c. Detach front brake hand lever (3) from master cylin-
der assembly.
2. If present, detach front brake lamp switch by removing
screw.
3. See Figure 2-24. Compress piston (2) and remove rub-
ber boot (1).
4. Depress piston assembly and remove internal snap ring
(3). Discard snap ring.
5. See Figure 2-25. Remove piston assembly (1-4) from
front master cylinder.
2-20
7035
Bleeder Valve (metric)
Figure 2-21. Draining Front Brake System
3
b0494x2x
2
1
7
1. Clamp Screws (2) (metric)
2. Clamp
3. Master Cylinder Cover Screws (2)
4. Banjo Washers (2)
5. Brake Line
6. Banjo Bolt (metric)
7. Front Brake Lamp Switch
8. Screw
Figure 2-22. Front Master Cylinder
2.10
4
5
6
8
2002 Buell X1: Chassis