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FRONT BRAKE MASTER CYLINDER AND HAND LEVER 2.10
REMOVAL
1.
Remove the deflectors, see
DLEBARS.
NOTES
Steps 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 (4-7 Nm).
b0979x2x
1.
Reservoir cover fasteners
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 bolt nut (metric)
10. Brake switch fastener
11. Brake switch
12. Brake switch terminal
13. Banjo bolt (metric)
14. Brake line
15. Copper washers
16. Pivot bolt
2.25 DEFLECTORS/HAN-
7
Figure 2-39. Front Brake Hand Lever Assembly
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 2-39.
Remove the banjo bolt (13) (metric)
and two copper washers (15) to disconnect brake line
(14) from master cylinder (4). Discard copper washers.
4.
Unplug terminal (12) to detach brake lamp switch (11).
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.
1
2
3
4
5
6
9
8
2006 Buell Ulysses: Chassis
16
15
14
12
13
11
10
2-27
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