Buell 2002 S3T - Rear Brake Line and Switch

2-30 2002 Buell S3T: Chassis
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REAR BRAKE LINE AND SWITCH 2.15
REMOVAL
1. Drain and discard brake fluid. See Step 1 under 2.13
REAR BRAKE MASTER CYLINDER.
11WARNING1WARNING
Any leak in brake system will adversely affect brake
operation. Damaged banjo bolt seating surfaces will leak
when reassembled. Prevent damage to seating surfaces
by carefully removing brake line components. Failure to
comply could result in death or serious injury.
2. See Figure 2-42. Remove banjo bolt (2) (metric) and two
banjo washers (3) to disconnect brake line (1) from rear
brake caliper. Discard banjo washers.
3. Remove banjo bolt and two banjo washers to disconnect
brake line from rear master cylinder. Discard banjo
washers.
4. Remove screw and clamp to detach brake line clamp
from frame.
5. See Figure 2-44. Remove bolt, washer, wireform and
brake line from under oil tank.
6. Remove wires from terminals (2,3) at top of brake lamp
switch (4). Unthread brake lamp switch from tee nut.
INSTALLATION
11WARNING1WARNING
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.
1. See Figure 2-45. Install wireform to rear brake line as
shown in figure.
2. From left side of vehicle, feed new brake line from rear
brake caliper mount forward to frame mount. Route
brake line to the right towards rear master cylinder.
3. See Figure 2-42. Install screw and clamp (1) to fasten
rear brake line to frame tube. Tighten to 10-12 ft-lbs (14-
16 Nm).
4. Place brake line inside wire guide (5) closest to master
cylinder.
5. See Figure 2-44. Attach the wireform under the oil tank
with bolt and washer.
Figure 2-42. Rear Brake Line and Switch
Figure 2-43. Rear Brake Caliper Banjo Bolt (Typical)
1
3
4
1. Clamp
2. Double Wire Terminal
3. Single Wire Terminal
4. Rear Brake Lamp Switch
5. Wire Guide
2
5
6483a
2
4
1
1. Brake Line
2. Banjo Bolt (metric)
3. Banjo Washers (2 - typical)
4. Bleeder Valve (metric)
3