Buell 2002 P3 - Page 96

2002 Buell P3: Chassis 2-21
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DISASSEMBLY
1. See Figure 2-28. Detach front brake hand lever.
a. Remove nut (1) (metric) from lever pivot.
b. Remove pivot bolt (2) from lever pivot.
2. Detach front brake hand lever (3) from master cylinder
assembly.
3. See Figure 2-29. Remove screw, lockwasher and washer
(1) holding front brake switch (3) to master cylinder
assembly. Remove switch.
4. See Figure 2-30. Compress piston (2) and remove rub-
ber boot (1).
5. Depress piston assembly and remove internal snap ring
(3). Discard snap ring.
6. See Figure 2-31. Remove piston assembly (1-4) from
front master cylinder.
CLEANING AND INSPECTION
11WARNING1WARNING
Clean brake system components using denatured alco-
hol. Do not use mineral-base cleaning solvents, such as
gasoline or paint thinner. Use of mineral-base solvents
causes deterioration of rubber parts that continues after
assembly. This could result in improper brake operation
which could result in death or serious injury.
1. Clean all parts with denatured alcohol or D.O.T. 4
BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Wipe dry with a clean, lint free cloth. Blow
out drilled passages and bore with a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages in bottom of reservoir.
2. Carefully inspect all parts for wear or damage and
replace as necessary.
3. Inspect piston bore in master cylinder housing for scor-
ing, pitting or corrosion. Replace housing if any of these
conditions are found.
4. Inspect outlet port that mates with brake line fitting. As a
critical sealing surface, replace housing if any scratches,
dents or other damage is noted.
5. Inspect boot for cuts, tears or general deterioration.
Replace as necessary.
Figure 2-28. Hand Lever
Figure 2-29. Front Brake Switch
Figure 2-30. Snap Ring
6488
2
3
1
1. Nut (metric)
2. Pivot Bolt
3. Hand Lever
3
1
2
1. Screw, Lockwasher and Washer
2. Tang
3. Front Brake Switch
6489
6490
2
1. Boot
2. Piston
3. Snap Ring
3
1