Buell 2009 XB Series Service Manual page 123

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Figure 2-44. Front Brake Fluid Line P-Clamp
Installation
1. See Figure 2-45. Connect the brake fluid line to master
cylinder/reservoir using two new copper washers (1) and
a banjo bolt (2).
2. Finger tighten the banjo bolt into master cylinder/reservoir.
3. Route the fluid line from the master cylinder to the caliper
in front of the lower fork clamp and between the forks.
NOTE
Use only new copper crush washers with D.O.T. 4 brake fluid.
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)
4. Connect the brake fluid line to caliper using two new
copper washers and a banjo bolt.
5. Finger tighten the banjo bolt into the front caliper.
6. Tighten the master cylinder/reservoir banjo bolt to 16-20
ft-lbs (22-27 Nm).
7. Tighten the caliper banjo bolt to 16-20 ft-lbs (22-27 Nm).
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
8. Fill the master cylinder/reservoir and bleed the brakes.
See 1.7 BRAKE SYSTEM
9. Install and tighten the P-clamp (3) on the front fork clamp.
Tighten to 36-60 in-lbs (4-7 Nm).
MAINTENANCE.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
10. Test the brake lamp.
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1. Washer
2. Banjo bolt
3. P-clamp fastener
Figure 2-45. Brake Fluid Line
CALIPER: REMOVAL AND INSTALLATION
Removal
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).
Remove brake line components carefully. Damage to
seating surfaces can cause leakage. (00320a)
2. See Figure 2-46. Disconnect brake line (1) at caliper (2).
3. Remove caliper mounting fasteners (3).
4. Slide caliper down the rotor to clear fork lower and then
remove off rotor.
2009 XB Service: Chassis 2-45
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