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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 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 contaminate with mineral oil or
other solvents. Wipe dry with a clean, lint free cloth. Blow
out drilled passages and bore with a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages in bottom of reservoir.
2.
Carefully inspect all parts for wear or damage and
replace as necessary.
3.
Inspect piston bore in master cylinder housing for scor-
ing, pitting or corrosion. Replace housing if any of these
conditions are found.
4.
Inspect outlet port that mates with brake line fitting. As a
critical sealing surface, replace housing 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 with a new snap ring (6).
3.
Install ridge on boot (5) into groove on piston (4).
4.
See
Figure 2-23.
Install front brake hand lever.
a.
Align hole in lever (3) with hole in master cylinder
assembly.
b.
Lubricate pivot bolt (2) with LOCTITE ANTI-SEIZE.
c.
Install pivot bolt through top of assembly. Tighten to
4-13 in-lbs (0.5-1.5 Nm).
d.
Install nut (1) (metric). Tighten to 44-62 in-lbs (5-7
Nm).
5.
See
Figure 2-22.
Install front brake lamp switch (7).
a.
Attach front brake lamp switch with screw (8).
Tighten to 7-13 in-lbs (1-2 Nm).
b.
Test switch action. Tang on switch must release
when hand lever is moved.
2002 Buell X1: Chassis
WARNING
6488
2
3
1.
Nut (metric)
2.
Pivot Bolt
3.
Hand Lever
Figure 2-23. Hand Lever
6490
1.
Boot
2.
Piston
3.
Snap Ring
Figure 2-24. Snap Ring
6491
1
3
2
1.
Spring
2.
Primary Cup
3.
Secondary Cup
4.
Piston
5.
Boot
6.
Snap Ring
Figure 2-25. Piston Assembly
1
1
2
3
4
5
6
2-21
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