2005 Buell Firebolt: Chassis 2-31
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INSTALLATION
CAUTION
To avoid leakage, verify that gaskets, banjo bolt, hydrau-
lic brake line and master cylinder bore are completely
clean.
1. See Figure 2-37. Connect brake line (13) to master cylin-
der (4) using two new copper washers (14) and a banjo
bolt (12) (metric). Loosely install bolt into master cylinder.
2. Route the brake line from the master cylinder to the cali-
per. See D.1 HOSE AND WIRE ROUTING for front brake
line routing.
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 gaskets, banjo bolt, hydrau-
lic brake line and caliper bore are completely clean.
3. Install brake line to caliper.
a. See Figure 2-42. Install new copper washer, brake
line (2), new copper washer and wire form (3) onto
banjo bolt (5).
b. Finger tighten banjo bolt (5) onto front caliper being
careful not to pinch wire form (3) while tightening,
wire form should rotate around banjo bolt freely.
c. Twist brake line (2) into wire form (3) spiral and clock
wire form against bleeder valve (4).
4. Tighten p-clamp with fastener (1) on lower triple clamp to
36-60 in-lbs (4-7 Nm).
5. See Figure 2-37. Tighten master cylinder banjo bolt (12)
(metric) to 16-20 ft-lbs (22-27 Nm).
6. See Figure 2-42. Tighten brake caliper banjo bolt (5)
(metric) to 16-20 ft-lbs (22-27 Nm).
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)
7. Install bleeder valve if removed. Refill master cylinder
and bleed brakes. See 1.7 BRAKE SYSTEM MAINTE-
NANCE.
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)
8. Turn ignition key switch to ON. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
LOCK.
Figure 2-43. Front Brake Line
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