Front Brake Master Cylinder And Hand Lever 2.10 - Buell 2007 LIGHTNING Service Manual

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FRONT BRAKE MASTER CYLINDER AND HAND LEVER 2.10

REMOVAL
NOTES
Steps 1 is not required for removing the master cylinder
assembly from the handlebars. Do not disassemble mas-
ter cylinder unless problems are experienced.
If servicing an XB9SX model, see
HANDLEBARS (XB9SX).
CAUTION
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
performed. Failure to comply can result in cosmetic dam-
age. (00239b)
1
CAUTION
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
attention. Use in well ventilated area. KEEP OUT OF
REACH OF CHILDREN. (00240a)
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
1.
2.25 DEFLECTORS/
Damaged banjo bolt seating surfaces will leak when reas-
sembled. Prevent damage to seating surfaces by carefully
removing brake line components.
2.
3.
4.
7
Figure 2-37. Front Brake Hand Lever Assembly
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).
NOTE
See Figure 2-37. Remove the banjo bolt (13) (metric)
and two copper washers (15) to disconnect brake line
(14) from master cylinder (4). Discard copper washers.
Unplug terminal (12) to detach brake lamp switch (11).
NOTES
The individual parts of the brake lamp switch are not ser-
viceable. Replace switch upon failure.
For XB9SX see 2.25 DEFLECTORS/HANDLEBARS
(XB9SX).
Remove mounting clamp fasteners (5) (metric) to detach
master cylinder reservoir (4) from handlebar.
1
2
3
4
5
6
9
10
8
2007 Buell Lightning: Chassis
16
15
14
12
13
11
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