Buell 2003XB9S Service Manual page 138

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DISASSEMBLY
1. See Figure 2-50. Slide rubber boot on rod assembly (3)
away from master cylinder body (1).
2. Depress rod assembly (3) and remove internal circlip (2).
Discard circlip.
3. Remove piston assembly (4) from master cylinder body
(1).
4. Loosen adjuster locknut on the rod assembly (3).
5. Remove the clevis from the rod assembly (3).
NOTE
Do not disassemble master cylinder unless problems are
experienced. Discard all seals during the disassembly proce-
dure. Install a complete rebuild kit upon assembly.
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. Thoroughly clean master cylinder and all brake system
components. Stand master cylinder on wooden block or
towel to protect seating surfaces.
a. Examine walls of master cylinder reservoir for
scratches and grooves. Replace if damaged.
b. Verify that vent holes on master cylinder are com-
pletely open and free of dirt or debris.
2. Inspect boot on front of master cylinder for cuts, tears or
general deterioration. Replace if necessary.
WARNING
ASSEMBLY
1. Obtain PISTON ASSEMBLY KIT.
6506
4
5
1. Master cylinder body
2. Circlip
3. Rod assembly
4. Piston assembly
5. Seals
Figure 2-50. Master Cylinder Internal
2. See Figure 2-50. Assemble new piston components
placing small end of spring behind primary seal of piston
(4).
3. Lubricate master cylinder body (1) and piston seals (5)
with D.O.T. 4 BRAKE FLUID.
4. Place round side of rod assembly (3) over piston.
Depress piston (4) into master cylinder body (1) and
secure with a new circlip (2).
11 1
WARNING
Circlip must be snapped into the groove of the master
cylinder body. If the circlip is not properly installed,
improper brake operation could result in death or serious
injury.
5. Tuck rubber boot on rod assembly (3) into master cylin-
der body (1).
2003 Buell XB9S: Chassis
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2
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WARNING
2-35