Front Brake Line - Buell 2006 P3 Service Manual

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FRONT BRAKE LINE

REMOVAL
IMPORTANT NOTE
Always drain brake fluid into a suitable container. Dis-
card used fluid according to local laws.
1. Drain and discard brake fluid. See Step 1 under
FRONT BRAKE MASTER
a0215a2x
4
5
1. Master cylinder banjo bolt (metric)
2. Banjo washers (2)
3. Brake line
4. Screw
5. Brake line clamp
6. Caliper banjo bolt (metric)
7. Banjo washers (2)
Figure 2-45. Front Brake Line
2. See Figure 2-45. Remove screw (4) to detach brake line
clamp (5) from right side of lower triple clamp. Remove
brake line from wireform.
2-32 2006 Buell P3: Chassis
2.10
CYLINDER.
3
2
1
6
7
IMPORTANT NOTE
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
3. Remove master cylinder banjo bolt (1) (metric) and two
banjo washers (2) to disconnect brake line from master
cylinder. Discard banjo washers.
4. Remove caliper banjo bolt (6) (metric) and two banjo
washers (7) to disconnect brake line from caliper. Dis-
card banjo washers.
5. Carefully inspect the brake line for dents, cuts or other
defects. Replace the brake line if any damage is noted.
INSTALLATION
11 1
WARNING
Use only new copper 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
IMPORTANT NOTE
To avoid leakage, ensure that banjo washers, banjo bolt,
hydraulic brake line and master cylinder bore are com-
pletely clean.
1. See Figure 2-45. Connect brake line to master cylinder
using two new banjo washers (2) and banjo bolt (1) (met-
ric). Loosely install bolt into master cylinder.
2. From the master cylinder, the brake line runs downward
in front of the right handlebar, where it turns inboard at
the upper triple clamp. Loosely install clamp (5) with
screw (4) to attach front brake line to right side of lower
triple clamp. Position brake line in wireform.
3. Connect brake line to caliper using two new banjo wash-
ers (7) and banjo bolt (6) (metric). Tighten banjo bolt (6)
to 16-20 ft-lbs (22-27 Nm).
4. Tighten clamp screw (4) on lower triple clamp to 36-60
in-lbs (4-7 Nm).
5. Tighten master cylinder banjo bolt (1) (metric) to 16-20 ft-
lbs (22-27 Nm).
6. Install bleeder valve if removed. Refill master cylinder
and bleed brakes.
11 1
WARNING
Check for proper brake lamp operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper brake lamp operation could
result in death or serious injury.
7. Turn ignition key switch to IGN. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
LOCK.
2.12
WARNING
WARNING