Buell 2002 S3T - Front Brake Line

2-24 2002 Buell S3T: Chassis
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FRONT BRAKE LINE 2.12
REMOVAL
1. Drain and discard brake fluid. See Step 1 under 2.11
FRONT BRAKE CALIPER.
2. See Figure 2-31. Remove screw to detach brake line
clamp from right side of lower triple clamp.
CAUTION
Cover painted surfaces and right handlebar switches and
use care when removing brake reservoir cover and add-
ing D.O.T. 4 brake fluid. Spilling D.O.T. 4 brake fluid on
painted surfaces will result in cosmetic damage. Spilling
brake fluid on switches may render them inoperative.
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.
3. Remove master cylinder banjo bolt (metric) and two
banjo washers to disconnect brake line from master cyl-
inder. Discard banjo washers.
4. Remove caliper banjo bolt and two banjo washers to dis-
connect brake line from caliper. Discard banjo washers.
5. Carefully inspect the brake line for dents, cuts or other
defects. Replace the brake line if any damage is noted.
INSTALLATION
11WARNING1WARNING
Use only copper crush 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.
CAUTION
To avoid leakage, verify that banjo washers, banjo bolt,
hydraulic brake line and master cylinder bore are com-
pletely clean.
1. See Figure 2-31. Connect brake line to master cylinder
using two new banjo washers and banjo bolt (metric).
2. From the master cylinder, the brake line runs downward
in front of the right handlebar, where it turns inboard at
the upper triple clamp. Loosely install clamp with screw
to attach front brake line to right side of lower triple
clamp.
3. Connect brake line to caliper using two new banjo wash-
ers and banjo bolt. Loosely install bolt into caliper.
4. Tighten clamp screw on lower triple clamp to 30-35 in-lbs
(3-4 Nm)
5. Tighten master cylinder banjo bolt (metric) to 16-20 ft-lbs
(22-27 Nm).
6. Tighten brake caliper banjo bolt to 16-20 ft-lbs (22-27
Nm).
CAUTION
Cover painted surfaces and right handlebar switches and
use care when removing brake reservoir cover and add-
ing D.O.T. 4 brake fluid. Spilling D.O.T. 4 brake fluid on
painted surfaces will result in cosmetic damage. Spilling
brake fluid on switches may render them inoperative.
7. Install bleeder valve if removed. Refill master cylinder
and bleed brakes. See 1.5 BRAKES
8. Turn ignition key switch to IGN. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
OFF.
Figure 2-31. Front Brake Line
b0364x2x
Banjo Bolt
Banjo
Washers (2)
Brake Line
Wire Guide
Banjo Bolt
Banjo
Washers (2)
Screw