Front Brake Master Cylinder And Hand Lever 2.10 - Buell 2004 XB9S Service Manual

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FRONT BRAKE MASTER CYLINDER AND HAND LEVER 2.10

REMOVAL
NOTE
Steps 1 is not required for removing the master cylinder
assembly from the handlebars. Do not disassemble master
cylinder unless problems are experienced.
1. Drain brake fluid into a suitable container. Discard used
fluid according to local laws.
a. Install a length of plastic tubing over caliper bleeder
valve. Place free end in a suitable container.
b. Open bleeder valve (metric) about 1/2-turn.
c. Pump brake hand lever to drain brake fluid.
d. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm).
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1. Reservoir cover fasteners
2. Reservoir cover
3. Reservoir cover gasket
4. Master cylinder reservoir
5. Master cylinder housing fasteners (metric)
6. Piston assembly
7. Rubber boot
8. Brake hand lever
9. Pivot bolt nut (metric)
10. Brake switch fastener
11. Brake switch
12. Brake switch terminal
13. Banjo bolt (metric)
14. Brake line
15. Copper washers
16. Pivot bolt
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
2.
3.
The individual parts of the brake lamp switch are not service-
able. Replace switch upon failure.
4.
7
Figure 2-37. Front Brake Hand Lever Assembly
CAUTION
See Figure 2-37. Remove the banjo bolt (13) (metric)
and two copper washers (15) to disconnect brake line
(14) from master cylinder (4). Discard copper washers.
Unplug terminal (12) to detach brake lamp switch (11).
NOTE
Remove mounting clamp fasteners (5) (metric) to detach
master cylinder reservoir (4) from handlebar.
1
2
3
4
5
6
9
10
8
2004 Buell Lightning: Chassis
16
15
14
12
13
11
2-25