Front Master Cylinder - Buell XB 2008 Series Service Manual

from the brake pivot shaft (17) to detach the brake hand
lever (8).
2. On all other models, remove pivot bolt nut (10) (metric)
and pivot bolt (17) to detach the brake hand lever.
3. Detach front brake hand lever (8).
4. Detach front brake switch (12) by removing the brake
switch fastener (11).

Front Master Cylinder

1. See Figure 2-34. Remove reservoir cover (2) by removing
cover fasteners (1).
2. Drain and discard used brake fluid according to local laws.
3. Remove rubber boot (7) and discard.
4. See Figure 2-35. Depress piston assembly (1) and remove
internal circlip (2) and discard.
5. See Figure 2-34. Remove piston assembly (6) from master
cylinder reservoir (4) and discard.
sm00529
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2
1. Piston assembly
2. Circlip
Figure 2-35. Piston Assembly in Master Cylinder
CLEANING AND INSPECTION
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)
1. Clean all parts with denatured alcohol or D.O.T. 4 BRAKE
FLUID. Do not contaminate with mineral oil or other
solvents. Wipe dry with a clean, lint free cloth. Blow out
drilled passages and bore with a clean air supply. Do not
use a wire or similar instrument to clean drilled passages
in bottom of reservoir.
2-26 2008 XB Service: Chassis
2. Inspect piston bore in master cylinder housing for scoring,
pitting or corrosion. Replace housing if any of these condi-
tions are found.
3. Inspect outlet port that mates with brake line fitting. As a
critical sealing surface, replace housing if any scratches,
dents or other damage is noted.
ASSEMBLY
Front Master Cylinder
1. Obtain PISTON ASSEMBLY KIT.
2. See Figure 2-36. Assemble new piston components, pla-
cing small end of spring (5) behind primary seal of piston
(4).
3. Lubricate master cylinder body and piston seals with DOT
4 brake fluid.
Be sure circlip snaps in place. An unsecured circlip can
cause brake failure, which could result in death or serious
injury. (00513b)
4. See Figure 2-34. Insert piston assembly (6), spring first,
into master cylinder reservoir (4).
5. See Figure 2-35. Secure piston assembly (1) with a new
circlip (2).
6. See Figure 2-36. Install ridge on rubber boot (1) into
groove on piston (3).
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1
1. Ridge on rubber boot
2. Circlip
3. Groove on piston
4. Primary seal of piston
5. Spring
Figure 2-36. Front Master Cylinder Piston Assembly
Brake Hand Lever
1. See Figure 2-34. Lubricate pivot bolt (17) with LOCTITE
ANTI-SEIZE.
2. Align hole in brake hand lever (8) with hole in hand lever
pivot. Install pivot bolt (17) through top of hand lever pivot
5
4
3