Buell 2003XB9S Service Manual page 68

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BRAKE PEDAL ADJUSTMENT
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WARNING 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.
Check rear brake pedal operation:
Before every ride.
At the 1000 mile (1600 km) service interval.
At every 5000 mile (8000 km) service interval thereafter.
NOTE
See Figure 1-11. On the very end of the threaded brake
rod, are two flat sides (2). To ensure proper thread
engagement with the clevis (3), the flat sides must
extend below the extruded nut (1) in the clevis by at least
one full thread. This is the minimum rod engagement.
Also, there should be a minimum of 0.030 in. (0.8 mm)
between brake rod end and brake pedal.
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WARNING WARNING
Threaded rod should not be adjusted to the point of con-
tacting brake pedal. Improper adjustment could result in
death or serious injury.
1. See Figure 1-12. Inspect for minimum and maximum
brake rod engagement in brake clevis (4). Adjust as
required.
2. Adjust brake pedal.
a. See Figure 1-12. Loosen locknut (3) while holding
rod adjuster (2). Move locknut away from top surface
of clevis (4).
b. Turn rod adjuster to set pedal height.
c. Return locknut (3) to fit flush against top surface of
clevis and tighten to 130-173.5 in-lbs (14.7-19.6
Nm).
NOTE
Brake pedal has no free play adjustment.
1-18 2003 Buell XB9S: Maintenance
b0615x1x
Minimum
Engagement
1. Extruded nut
2. Flat sides (on the end of the threaded brake rod)
3. Clevis
Figure 1-11. Critical Measurements with Typical
Brake Pedal
8349
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2
3
4
5
1. Bottom of master cylinder
2. Rod adjuster
3. Locknut
4. Clevis
5. Clevis pin
Figure 1-12. Rear Brake Pedal Pushrod Adjustment
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2
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