2-40 2005 Buell Firebolt: Chassis
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INSTALLATION
1. See Figure 2-56. Install brake line switch/banjo bolt with
new copper washers to the master cylinder. Tighten to
16-20 ft-lbs (22-27 Nm).
NOTE
Tighten the right side banjo bolt with FLARE NUT SOCKET
tool (SNAP-ON Part No. FRXM14) or a crowsfoot.
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.
2. Install brake line switch/banjo bolt and new copper wash-
ers to rear caliper. Tighten to 16-20 ft-lbs (22-27 Nm).
3. See Figure 2-55. Secure brake line (1) to left side of
swingarm with p-clamp (3), wire form (2), and tighten to
36-60 in-lbs (4-7 Nm). See D.1 HOSE AND WIRE
ROUTING for brake line routing.
4. See Figure 2-57. Connect brake line switch connector
underneath seat. See D.1 HOSE AND WIRE ROUTING
for brake line routing.
5. Install right heel guard. See 2.29 FOOTPEG, HEEL
GUARD AND MOUNT.
6. Bleed brakes. See BLEEDING BRAKES in 1.7 BRAKE
SYSTEM MAINTENANCE.
11WARNING1WARNING
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
7. Install negative battery cable and tighten to 72-96 in-lbs
(8-11 Nm). See 1.5 BATTERY MAINTENANCE.
11WARNING1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat can
shift causing loss of control, which could result in death
or serious injury. (00070a)
8. Install seat. See 2.38 SEAT.
11WARNING1WARNING
Be sure that all lights and switches operate properly
before operating motorcycle. Low visibility of rider can
result in death or serious injury. (00316a)
9. Turn ignition key ON, depress rear brake pedal and
check for proper brake light operation.
11WARNING1WARNING
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
high speeds can cause loss of control, which could
result in death or serious injury. (00289a)
10. Test ride motorcycle and check for proper brake opera-
tion.
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