Front Master Cylinder - Buell 2003XB9S Service Manual

HOME
DISASSEMBLY
Brake Hand Lever
1. See Figure 2-34. Remove pivot bolt nut (9) (metric) and
pivot bolt (16) from hand lever pivot.
2. Detach front brake hand lever assembly (8) from hand
lever pivot.
3. Detach front brake lamp switch (11) by removing the
switch fastener (10).

Front Master Cylinder

1. See Figure 2-34. Remove master cylinder cover (2) by
removing cylinder cover fasteners (1).
2. Discard excess brake fluid.
3. Remove rubber boot (7) and discard.
8424
1
1. Piston assembly
2. Circlip
Figure 2-35. Piston Assembly in Master Cylinder
4. See Figure 2-35. Depress piston assembly (1) and
remove internal circlip (2) and discard.
5. See Figure 2-34. Remove piston assembly (6) from front
master cylinder reservoir (4) and discard.
2
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. Inspect piston bore in master cylinder housing for scor-
ing, pitting or corrosion. Replace housing if any of these
conditions are found.
3. 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.
2003 Buell XB9S: Chassis
WARNING
2-25