Buell 2002 S3T Service Manual page 100

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CLEANING AND INSPECTION
11 1
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 could result in improper brake operation
which could result in death or serious injury.
1. Thoroughly clean master cylinder and all brake system
components. Stand master cylinder on wooden block or
towel to protect seating surfaces.
a. Examine walls of master cylinder reservoir for
scratches and grooves. Replace if damaged.
b. Verify that vent holes on master cylinder are com-
pletely open and free of dirt or debris.
2. Inspect boot on front of master cylinder for cuts, tears or
general deterioration. Replace if necessary.
ASSEMBLY
1. See Figure 2-37. Insert piston assembly (4), spring first,
into master cylinder.
2. Place round side of rod assembly (3) over piston.
Depress piston into master cylinder body (1) and secure
with a new snap ring (2).
3. Tuck rubber boot on rod assembly (3) into master cylin-
der body (1).
INSTALLATION
1. See Figure 2-36. Connect remote reservoir.
a. If removed, attach remote reservoir to frame using
screw. Tighten to 12-15 in-lbs (1-2 Nm).
b. Attach line to master cylinder using clamp.
2. See Figure 2-35. Attach master cylinder (3) to frame
using two screws (2) (metric). Tighten to 8-10 ft-lbs (11-
14 Nm).
11 1
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.
11 1
WARNING
Any leak in brake system will adversely affect brake
operation. To avoid leakage after assembly, verify that
gaskets, banjo bolt, hydraulic brake line and bore of
master cylinder are completely clean. Failure to comply
could result in death or serious injury.
3. See Figure 2-33. Connect brake line (3) to master cylin-
der (4) with two new banjo washers (2) and banjo bolt (1)
(metric). Tighten to 16-20 ft-lbs (22-27 Nm).
2-26 2002 Buell S3T: Chassis
WARNING
WARNING
WARNING
b0470x1x
1
2
3
4
1. Rubber Boot
2. Rod Adjuster
3. Locknut
4. Top Surface of Turn Buckle
Figure 2-34. Brake Push Rod
6546
1
5
4
3
1. Banjo Bolt (metric)
2. Screw (2) (metric)
3. Master Cylinder Body
4. Clamp
5. Remote Reservoir Hose
Figure 2-35. Master Cylinder Mounting
2
2