Removal: Ulysses; Installation: Lightning - Buell 2009 XB Series Service Manual

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INSTALLATION: LIGHTNING

PART NUMBER
SNAP-ON FRXB14 FLARE NUT SOCKET
1. See Figure 2-76. Install brake light 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 (Part No. SNAP-ON FRXB14) or a crowsfoot.
2. Install brake line banjo bolt and new copper washers to
rear caliper. Tighten to 16-20 ft-lbs (22-27 Nm).
3. See Figure 2-75. Secure brake line (1) to left side of
swingarm with p-clamp (2) and tighten to 36-60 in-lbs (4-
7 Nm). See D.1 APPENDIX D: HOSE AND WIRE
ROUTING for brake line routing.
4. See Figure 2-76. Connect brake line switch connector
underneath seat.
5. Install right heel guard. See
GUARD AND MOUNT: FIREBOLT/LIGHTNING.
6. Verify that the brake line fits the fender guide and install
rear fender. See 2.15 FENDERS.
7. Bleed brakes. See 1.7 BRAKE SYSTEM MAINTENANCE,
Bleeding Brakes.
8. Install negative battery cable and tighten to 72-96 in-lbs
(8-11 Nm). See 1.5 BATTERY
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
9. Install seat.
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. Turn ignition key ON, depress rear brake pedal and check
for proper brake light operation.
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
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)
11. Test ride motorcycle and check for proper brake operation.
TOOL NAME
2.34 FOOTPEG, HEEL
MAINTENANCE.

REMOVAL: ULYSSES

1. Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery by unthreading fastener removing
negative cable (black) from battery first. See
MAINTENANCE.
3. See Figure 2-78. Disconnect brake light connector from
under seat in the front of the battery.
4. 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 foot pedal to drain brake fluid.
d. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm).
5. See Figure 2-79. Remove the rear wheel fender. See
2.15 FENDERS.
Remove brake line components carefully. Damage to
seating surfaces can cause leakage. (00320a)
6. Remove banjo bolt (3) from rear caliper. Discard copper
washers.
7. Remove right side rider/passenger peg mount. See
2.35 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES
MODELS.
8. See Figure 2-80. Remove brake line switch/banjo bolt from
rear master cylinder. Discard copper washers.
9. Remove brake line bracket fasteners.
10. Remove brake line from motorcycle.
2009 XB Service: Chassis 2-65
1.5 BATTERY