Buell 2005 FIREBOLT - Page 99

2-38 2005 Buell Firebolt: Chassis
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INSTALLATION
1. See Figure 2-51. Install master cylinder (4) onto footpeg
mount with fasteners (11). Tighten to 72-96 in-lbs (8-
11 Nm).
2. Install rear brake switch (1) and banjo bolt (2) and new
copper crush washers (3). Tighten to 16-20 ft-lbs (22-
27 Nm).
3. Install footpeg mount to frame. See 2.29 FOOTPEG,
HEEL GUARD AND MOUNT.
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 after assembly, verify that banjo wash-
ers, banjo bolt, hydraulic brake line and bore of master
cylinder are completely clean.
4. See Figure 2-52. Connect remote reservoir.
a. If removed, attach remote reservoir (1) to frame
using clamp fastener (2). Tighten to 48-72 in-lbs
(5.4-8.1 Nm).
b. Attach hose (3) to rear brake reservoir using clamp.
5. See Figure 2-50. Connect brake line switch connector
under seat.
6. Install heel guard. See 2.29 FOOTPEG, HEEL GUARD
AND MOUNT.
7. Install rear brake pedal. See 2.9 BRAKE PEDAL.
8. Adjust rear brake pedal. See BRAKE PEDAL ADJUST-
MENT in 1.7 BRAKE SYSTEM MAINTENANCE.
9. Install master cylinder to brake pedal. See 2.9 BRAKE
PEDAL.
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. Add brake fluid and bleed brake system. See 1.7 BRAKE
SYSTEM MAINTENANCE.
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)
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)
11. Install seat. See 2.38 SEAT.