Buell XB 2010 Service Manual page 132

HOME
sm05439
6
3
5
4
2
1
1. Spring
2. Rubber cap
3. Piston
4. Rubber seal
5. Circlip
6. Rubber boot
Figure 2-63. Piston Set
MASTER CYLINDER/RESERVOIR:
INSTALLATION
1. See Figure 2-64. Install master cylinder/reservoir to
handlebar with clamp (1) and fasteners (2).
2. Position for rider posture and tighten to 80-90 in-lbs (9.0-
10.2 Nm).
3. If removed, install the front brake light switch (3).
a. Install brake light switch fastener (4) and washer (5).
b. Tighten to 7-10 in-lbs (0.8-1 Nm).
c. Push brake light socket connectors into brake light
switch spade terminals.
d. Test switch action. Tang on switch must release when
hand lever is moved.
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)
2-52 2010 XB Service: Chassis
4. Connect the brake fluid line (6) to the master cylinder/reser-
voir using two new copper washers (7) and banjo bolt (8)
and tighten to 16-20 ft-lbs (22-27 Nm).
NOTE
Use only new copper crush banjo washers 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.
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
5. Protect the body work from the brake fluid.
6. With the master cylinder in a level position, add D.O.T. 4
brake fluid until the level is above the LOWER line on the
sight gauge.
A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)
7. To verify operation of the relief port, actuate the brake
lever with the reservoir cover removed. A slight spurt of
fluid will break the surface if the relief port is open.
8. Bleed the front brake fluid lines. See
SYSTEM MAINTENANCE.
9. Attach reservoir cover (9), gasket (10) and diaphragm
(11). Tighten cover fasteners (12) to 9-13 in-lbs (1-1.5
Nm).
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
10. Test the brake light.
1.14 BRAKE