Front Brake: Six Piston Caliper - Buell XB 2010 Service Manual

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FRONT BRAKE: SIX PISTON CALIPER

MASTER CYLINDER RESERVOIR REMOVAL
1. On XB9SX, XB12X, XB12XT and XB12XP models, remove
the right deflector. See 2.28
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
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)
NOTE
Step 2 is not required for removing the master cylinder
assembly from the handlebars. Do not disassemble master
cylinder unless problems are experienced.
2. Drain brake fluid into a suitable container. Discard used
fluid according to local laws.
a. Install a length of plastic tubing over caliper bleeder
valve. Place free end in a suitable container.
b. Open bleeder valve (metric) about 1/2-turn.
c. Pump brake hand lever to drain brake fluid.
d. Tighten bleeder valve to 36-60 in-lbs (4-6.8 Nm).
NOTE
Damaged banjo bolt seating surfaces will leak when reas-
sembled. Prevent damage to seating surfaces by carefully
removing brake line components.
3. See Figure 2-73. Remove the banjo bolt (14) (metric) and
two copper washers (16) to disconnect brake line (15)
from master cylinder (4). Discard copper washers.
4. Unplug terminal (13) to detach brake lamp switch (12).
NOTE
The individual parts of the brake lamp switch are not service-
able. Replace switch upon failure.
5. Remove mounting clamp fasteners (5) (metric) to detach
master cylinder reservoir (4) from handlebar.
2-58 2010 XB Service: Chassis
DEFLECTORS.
sm00528
1
2
3
4
5
6
7
10
9
8
1. Reservoir cover fasteners (2)
2. Reservoir cover
3. Reservoir cover gasket
4. Master cylinder reservoir
5. Master cylinder housing fasteners (metric)
6. Piston assembly
7. Rubber boot
8. Brake hand lever
9. Pivot shaft riser, nut, and screw (XB9SX and
Ulysses models only)
10. Pivot bolt nut (metric) (models except XB9SX
and Ulysses models)
11. Brake switch fastener
12. Brake switch
13. Brake switch terminal
14. Banjo bolt (metric)
15. Brake line
16. Copper washers
17. Pivot bolt (all models except XB9SX and Ulysses
models)
18. Brake pivot shaft (XB9SX and Ulysses models
only)
Figure 2-73. Front Brake Hand Lever Assembly
2.10
18
17
16
15
14
13
12
11