Buell 2007 ULYSSES Service Manual page 158

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ASSEMBLY
Front Master Cylinder
1. Obtain PISTON ASSEMBLY KIT.
2. See Figure 2-40. Assemble new piston components
placing small end of spring (5) behind primary seal of
piston (4).
3. Lubricate master cylinder body and piston seals with
special lubricant found in the service parts kit.
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WARNING
When installing circlip to secure master cylinder, be sure
the circlip snaps into place. Failure to do so can result in
improper brake operation which could result in death or
serious injury.
4. See Figure 2-38. Insert piston assembly (6), spring first,
into master cylinder reservoir (4).
5. See Figure 2-39. Secure piston assembly (1) with a new
circlip (2).
6. See Figure 2-40. Install ridge on boot (1) into groove on
piston (3).
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2
1
1. Ridge on rubber boot
2. Circlip
3. Groove on piston
4. Primary seal of piston
5. Spring
Figure 2-40. Front Master Cylinder Piston Assembly
WARNING
5
4
3
Brake Hand Lever
1. See Figure 2-38. Lubricate pivot bolt (16) with LOCTITE
ANTI-SEIZE.
2. Align hole in hand lever (8) with hole in hand lever pivot
and install pivot bolt (16) through top of hand lever pivot
and tighten nut to 39-48 in-lbs (4.4-5.4 Nm).
INSTALLATION
1. See Figure 2-38. Install front brake lamp switch (11).
a. Install brake lamp switch (11) with switch fastener
(10) and tighten to 7-10 in-lbs (0.8-1.0 Nm).
b. Connect brake switch terminal (12) to brake lamp
switch (11).
c. Test switch action. Tang on switch must release
when hand lever is moved.
2. Install master cylinder to handlebar by fastening clamp
with fasteners. Position for rider posture and tighten to
80-90 in-lbs (9-10 Nm).
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WARNING
Use only new copper crush banjo washers (See Parts
Catalog for Part No.) with D.O.T. 4 brake fluid. Earlier sil-
ver 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.
11 1
WARNING
To avoid leakage, verify that banjo washers, banjo bolt,
hydraulic brake line and master cylinder bore are com-
pletely clean.
3. See Figure 2-38. Connect brake line to master cylinder
using two new copper washers (15) and banjo bolt (13)
(metric) and tighten to 16-20 ft-lbs (22-27 Nm).
2007 Buell Ulysses: Chassis
WARNING
WARNING
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