Front Brake Line - Buell 2002 X1 Handbook

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FRONT BRAKE LINE

REMOVAL
1. Drain and discard brake fluid.
2. See Figure 2-36. Remove screw (4) to detach brake line
clamp and wire guide (5) from right side of lower triple
clamp.
CAUTION
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
3. Remove master cylinder banjo bolt (1) (metric) and two
banjo washers (2) to disconnect brake line from master
cylinder. Discard banjo washers.
4. Remove caliper banjo bolt (6) (metric) and two banjo
washers (7) to disconnect brake line from caliper. Dis-
card gaskets.
5. Carefully inspect the brake line for dents, cuts or other
defects. Replace the brake line if any damage is noted.
INSTALLATION
CAUTION
To avoid leakage, verify that gaskets, banjo bolt, hydrau-
lic brake line and master cylinder bore are completely
clean.
1. See Figure 2-36. Connect brake line to master cylinder
using two new banjo washers (2) and banjo bolt (1)
(metric). Loosely install bolt into master cylinder.
2. See Figure 2-37. From the master cylinder, the brake line
runs downward in front of the right handlebar, where it
turns inboard at the upper triple clamp. Loosely install
clamp and wire guide (5) with screw (4) to attach front
brake line clamp to right side of lower triple clamp. Route
brake line through wire guide as shown in
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 gaskets, banjo bolt, hydrau-
lic brake line and caliper bore are completely clean.
3. See Figure 2-36. Connect brake line to caliper using two
new banjo washers (7) and banjo bolt (6). Loosely install
bolt into caliper.
2-26
Figure 2-37.
WARNING
b0364x2x
4
5
Lower Right Side-
Brake Caliper
1. Master Cylinder Banjo Bolt (metric)
2. Master Cylinder Banjo Washers (2)
3. Brake Line
4. Screw
5. Clamp and Wire Guide (not shown)
6. Caliper Banjo Bolt (metric)
7. Caliper Banjo Washers (2)
Figure 2-36. Front Brake Line
2.12
Top Right Side-
Master Cylinder
3
2
1
6
7
2002 Buell X1: Chassis