Buell 2003XB9S Service Manual page 130

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INSTALLATION
1. See Figure 2-34. Install front brake lamp switch (11).
a. Install brake lamp switch (11) with switch fastener
(10) and tighten to 7-10 in-lbs (0.8-1.0 Nm).
b. Connect brake switch terminal (12) to brake lamp
switch (11).
c. Test switch action. Tang on switch must release
when hand lever is moved.
2. Install master cylinder to handlebar by fastening clamp
with fasteners and tighten to 80-90 in-lbs (9-10 Nm).
11 1
WARNING
Use only copper crush 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.
11 1
WARNING
To avoid leakage, verify that banjo washers, banjo bolt,
hydraulic brake line and master cylinder bore are com-
pletely clean.
3. See Figure 2-34. Connect brake line to master cylinder
using two new copper washers (15) and banjo bolt (13)
(metric) and tighten to 16-20 ft-lbs (22-27 Nm).
4. See Figure 2-37. Verify brake lamp switch wires are tight.
5. See Figure 2-34. Remove two master cylinder cover
screws (1), cover (2) and cover gasket (3).
6. See Figure 2-38. 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 mas-
ter 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. Bleed brake system. See
NANCE.
9. See Figure 2-34. Attach master cylinder cover (2) and
cover gasket (3). Tighten two cover fasteners (1) 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.
WARNING
WARNING
WARNING
1.7 BRAKE SYSTEM MAINTE-
WARNING
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 ON. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
OFF.
8923
Figure 2-37. Front Brake Light Switch Connector
b0613x2x
Figure 2-38. Brake Fluid Level
(Standard Brake Reservoir Shown)
2003 Buell XB9S: Chassis
WARNING
2-27