Buell 2003XB9S Service Manual page 141

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INSTALLATION
1. See Figure 2-53. Install brake line switch/banjo bolt with
new copper washers to the master cylinder. Tighten to
16-20 ft-lbs (22-27 Nm).
NOTE
Tighten the right side banjo bolt with FLARE NUT SOCKET
tool (SNAP-ON Part No. FRXM14) or a crowsfoot.
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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.
2. Install brake line switch/banjo bolt and new copper wash-
ers to rear caliper. Tighten to 16-20 ft-lbs (22-27 Nm).
3. See Figure 2-52. Secure brake line (1) to left side of
swingarm with p-clamp (3), wire form (2), and tighten to
36-60 in-lbs (4-7 Nm). See
ROUTING for brake line routing.
4. See Figure 2-54. Connect brake line switch connector
underneath seat. See D.1 HOSE AND WIRE ROUTING
for brake line routing.
5. Install right heel guard. See
GUARD AND MOUNT.
6. Bleed brakes. See BLEEDING BRAKES
SYSTEM MAINTENANCE.
2-38 2003 Buell XB9S: Chassis
WARNING
D.1 HOSE AND WIRE
2.30 FOOTPEG, HEEL
in 1.7 BRAKE
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WARNING
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
7. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See 1.5 BATTERY MAINTENANCE.
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WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
8. Install seat. See 2.41 SEAT.
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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.
9. Turn ignition key ON, depress rear brake pedal and
check for proper brake light operation.
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WARNING
After completing repairs or bleeding the system, always
test motorcycle brakes at low speed. If brakes are not
operating properly or braking efficiency is poor, testing
at high speeds could result in death or serious injury.
10. Test ride motorcycle and check for proper brake opera-
tion.
WARNING
WARNING
WARNING
WARNING