Buell X1 2002 Service Manual page 103

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INSTALLATION
11 1
WARNING
If rear brake line must be replaced, use only the brake
line with the olive drab coating on the metal portion of
the line (See Parts Catalog for Part No.) with DOT 4 brake
systems. The previous black metal brake line is NOT
compatible with DOT 4 brake fluid. Failure to comply may
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
NOTE
If replacing rear brake light switch, place brake line in vise
gently (securing hexagonal rear brake light switch fitting) to
prevent bending brake line while removing or installing rear
brake lamp switch.
1. Coat threads of rear brake lamp switch with LOCTITE
PIPE SEALANT WITH TEFLON and install to brake line.
Tighten switch to 84-96 in-lbs (10-11 Nm). Tighten as
required to orient terminals perpendicular to brake line.
2. Remove frame side fasteners from rear tie bar (locknut,
washer and bolt). Discard locknut. NOTE: Using a 3 inch
extension and deep well swivel socket simplifies removal
of the tie bar fasteners.
3. See Figure 2-53. Working from the right side, install
brake line and align metal portion of brake line with rear
master cylinder. Route caliper side of brake line in front
of tie bar and through rear fender opening to rear caliper.
4. Carefully push up on bottom of oil tank and position rear
brake line tangs under studs on the bottom of the oil
tank. Lower oil tank allowing studs to engage pockets in
frame.
5. See Figure 2-54. Install loop cushioned clamp to brake
line and then to bolt side of tie bar fasteners. Loop clamp
is oriented down and to the left. Install tie bar to frame
with bolt, washer and loop cushioned clamp on lower
side of tie bar and new locknut on upper side of tie bar.
Tighten tiebar bolt to 30-33 ft-lbs (41-45 Nm).
11 1
WARNING
Use only new black 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.
6. Install rear master cylinder banjo bolt with new banjo
washers and torque to 16-20 ft-lbs (22-27 Nm).
7. Install rear caliper banjo bolt with new banjo washers
and torque to 16-20 ft-lbs (22-27 Nm). NOTE: Removing
inner fender TORX screw and plastic washer will assist in
tightening banjo bolt. If TORX screw and plastic washer
are removed, tighten to 72-96 in-lbs (8-11 Nm) when
installing.
2002 Buell X1: Chassis
WARNING
WARNING
7090
Figure 2-51. Rear Brake Light Switch
8213
Cable Tie
Cable Tie
Figure 2-52. Rear Brake Line - Left Side
8215
Rear Fender
Opening
Rear Brake
Line
Figure 2-53. Rear Brake Line Routing
Terminals
Rear Brake
Light Switch
Rear Caliper
2-35