Rear Brake Line And Switch - Buell 2002 X1 Handbook

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REAR BRAKE LINE AND SWITCH

REMOVAL
1. Position motorcycle on a suitable lift and position REAR
WHEEL SUPPORT STAND (Part No. B41174) under the
swing arm. Secure motorcycle to lift.
2. Remove seat. See 2.40 SEAT.
11 1
WARNING
To protect agsint shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
11 1
WARNING
Always disconnect the negative battery cable first. If the
positive battery cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion which could result in death or seri-
ous injury.
3. Disconnect both battery cables from battery, negative (-)
cable first. See 1.5 BATTERY.
4. Cut cable tie holding oxygen sensor connector to battery
strap. Remove battery strap and battery.
5. Remove rear brake fluid reservoir cap and drain brake
fluid from rear brake system into suitable container. See
Step 1 (Removal) in 2.13 REAR BRAKE MASTER CYL-
INDER.
6. Remove two top bolts from oil tank.
7. See Figure 2-50. Cut two cable ties holding rear brake
reservoir hose to rear brake line above rear master cylin-
der on right side of motorcycle.
8. See Figure 2-51. Disconnect two wires from rear brake
light switch.
CAUTION
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
9. Remove rear master cylinder banjo bolt and two banjo
washers. Discard banjo washers.
10. See Figure 2-49. Remove rear brake caliper banjo bolt
and two banjo washers. Discard banjo washers.
11. Carefully push up on bottom of oil tank to allow rear
brake line tangs to be freed from studs on the bottom of
the oil tank.
12. See Figure 2-52. Cut cable tie on wiring harness and
cable tie on vent tube on left side of bike.
13. Slide rear brake line into area where battery usually sits
and then off of bike through left side of frame.
NOTE
If replacing rear brake light switch, place brake line in vise
gently (securing hexagonal rear brake light switch fitting) to
prevent bending brake line while removing or installing rear
brake lamp switch.
2-34
WARNING
WARNING
14. See Figure 2-51. Remove rear brake light switch from
brake line.
7036
2
1
3
1. Banjo Bolt (metric)
2. Banjo Washers (2)
3. Brake Line
4. Bleeder Valve (metric)
Figure 2-49. Rear Brake Caliper Banjo Bolt
8212
Reservoir Hose
Cable Ties
Banjo Bolt
Figure 2-50. Rear Master Cylinder Banjo Bolt
2.15
4
2002 Buell X1: Chassis