Buell 2002 X1 Handbook page 69

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INSTALLATION
1. See Figure 2-22. Fasten master cylinder to handlebar by
installing clamp (2) and screws (1) (metric). Tighten to
80-90 in-lbs (9-10 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, verify that banjo washers, banjo bolt,
hydraulic brake line and master cylinder bore are com-
pletely clean.
2. Connect brake line (5) to master cylinder using two new
banjo washers (4) and banjo bolt (6) (metric). Tighten to
16-20 ft-lbs (22-27 Nm).
3. See Figure 2-26. Verify brake lamp switch wires are tight.
4. See Figure 2-27. Install mirror parallel to handlebars.
5. Remove two master cylinder cover screws, cover and
cover gasket.
6. See Figure 2-28. With the master cylinder in a level posi-
tion, add D.O.T. 4 BRAKE FLUID. Bring fluid level to
within 1/8 in. (3.2 mm) of molded boss inside front master
cylinder reservoir.
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
which could result in death or serious injury.
7. Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
components are working properly.
8. Attach master cylinder cover and cover gasket with two
cover screws. Tighten to 9-13 in-lbs (1.0-1.5 Nm).
11 1
WARNING
Always test motorcycle brakes at low speed after servic-
ing or bleeding system. To prevent death or serious
injury, Buell recommends that all brake repairs be per-
formed by a Buell dealer or other qualified technician.
9. Bleed brake system. See
11 1
WARNING
Check for proper brake lamp operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper brake lamp operation could
result in death or serious injury.
10. Turn ignition key switch to IGN. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
LOCK.
2-22
WARNING
WARNING
WARNING
1.7 BRAKES.
WARNING
7043
Figure 2-26. Brake Lamp Switch Connectors
7044
Figure 2-27. Mirror Installation
b0613x2x
Brake Fluid Level
Figure 2-28. Brake Fluid Level
Connectors
2002 Buell X1: Chassis