Buell X1 2002 Service Manual page 93

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CAUTION
To avoid leakage, verify that banjo washers, banjo bolt,
hydraulic brake line and caliper bore are completely
clean.
4. Connect brake line (1) to caliper using two new banjo
washers (3) and banjo bolt (2) (metric). Tighten to 16-20
ft-lbs (22-27 Nm).
5. See Figure 2-34. Remove both master cylinder cover
screws (2). Remove master cylinder cover (1) plastic
insert and gasket.
6. With the master cylinder in a level position, verify that the
brake fluid level is 1/8 in. (3.2 mm) from molded boss
inside reservoir. Add D.O.T. 4 BRAKE FLUID if neces-
sary.
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WARNING
Verify proper operation of the master cylinder relief port.
A plugged or covered relief port can cause brake drag or
lockup, which may result in loss of vehicle control. These
events could result in death or serious injury.
7. Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
components are working properly.
8. See Figure 2-34. Install master cylinder cover, plastic
insert and gasket with two screws. Tighten to 9-13 in-lbs
(1-2 Nm).
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WARNING
Always test motorcycle brakes at low speed after servic-
ing or bleeding system. To prevent death or serious
injury, Buell recommends that all brake repairs be per-
formed by a Buell dealer or other qualified mechanic.
9. Depress front brake lever several times to set brake pads
to proper operating position within caliper. Bleed brake
system. See 1.7 BRAKES.
10. Check clearance between front caliper mounting bolts
and T-40 TORX screws on rotor. See
11 1
WARNING
Check for proper brake lamp operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper brake lamp operation could
result in death or serious injury.
11. Turn ignition key switch to IGN. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
LOCK.
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to "wear in" properly with the brake
rotor.
2002 Buell X1: Chassis
WARNING
WARNING
1.7 BRAKES.
WARNING
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Figure 2-33. Installing Brake Pads
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2
1. Master Cylinder Cover
2. Screws (2)
Figure 2-34. Master Cylinder Cover (Typical)
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Figure 2-35. Front Master Cylinder Gasket
This surface
against brake rotor
1
2
2-25