Brake System Maintenance; Bleeding Brakes - Buell XB9R 2003 Service Manual

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BRAKE SYSTEM MAINTENANCE

GENERAL
Check brake fluid level and condition:
At the 1000 mile (1600 km) service interval.
At every 5000 mile (8000 km) service interval thereafter.
When storing or removing the motorcycle for the season.
Replace D.O.T. 4 BRAKE FLUID:
Every 2 years.
Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
described.
Inspect front and rear brake lines and replace as required:
At the 1000 mile (1600 km) service interval.
At every 2500 miles (4000 km) service interval thereaf-
ter.
Every 4 years.
Inspect caliper and master cylinder seals and replace as
required:
At the 1000 mile (1600 km) service interval.
At every 2500 miles (4000 km) service interval thereaf-
ter.
Every 2 years.
If determining probable causes of poor brake operation, see
Table 1-6.

BLEEDING BRAKES

1 1
WARNING WARNING
D.O.T. 4 brake fluid can cause irritation of eyes and skin,
and may be harmful if swallowed. If large amount of fluid
is swallowed, induce vomiting by administering two
tablespoons of salt in a glass of warm water. Call a doc-
tor. In case of contact with skin or eyes, flush with plenty
of water. Get medical attention for eyes. KEEP BRAKE
FLUID OUT OF THE REACH OF CHILDREN. Failure to
comply could result in death or serious injury.
1 1
WARNING WARNING
Never mix D.O.T. 4 with other brake fluids (such as D.O.T.
5). Use only D.O.T. 4 brake fluid in motorcycles that spec-
ify D.O.T. 4 fluid on the reservoir cap. Mixing different
types of fluid may adversely affect braking ability and
lead to brake failure which could result in death or seri-
ous injury.
1 1
WARNING WARNING
Use only fresh, uncontaminated D.O.T. 4 fluid. Cans of
fluid that have been opened may have been contami-
nated by moisture in the air or dirt. Use of contaminated
brake fluid may adversely affect braking ability and lead
to brake failure which could result in death or serious
injury
1 1
WARNING 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.
1 1
WARNING WARNING
Clean brake system components using denatured alco-
hol. Do not use mineral-base cleaning solvents, such as
gasoline or paint thinner. Use of mineral-base solvents
causes deterioration of rubber parts that continues after
assembly. This may result in improper brake operation
which could result in death or serious injury.
1 1
WARNING WARNING
Always test motorcycle brakes at low speed after servic-
ing or bleeding system. To prevent death or serious
injury, Buell recommends that all brake repairs be per-
formed by a Buell dealer or other qualified technician.
CAUTION
Cover molded-in-color surfaces and right handlebar
switches and use care when removing brake reservoir
cover and adding D.O.T. 4 brake fluid. Spilling D.O.T. 4
brake fluid on molded-in-color surfaces will result in cos-
metic damage. Spilling brake fluid on switches may ren-
der them inoperative.
2003 Buell XB9R: Maintenance
1.6
1-11