2-42 2006 Buell Lightning: Chassis
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INSTALLATION
1. See Figure 2-57. 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 new copper crush banjo washers (See Parts
Catalog for Part No.) with D.O.T. 4 brake fluid. Earlier sil-
ver 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 banjo bolt and new copper washers to
rear caliper. Tighten to 16-20 ft-lbs (22-27 Nm).
3. See Figure 2-56. Secure brake line (1) to left side of
swingarm with p-clamp (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 2-58. Connect brake line switch connector
underneath seat. See D.1 HOSE AND WIRE ROUTING
for brake line routing.
5. Install right heel guard. See 2.32 FOOTPEG, HEEL
GUARD AND MOUNT.
6. On XB12Ss models verify that the brake line fits the
fender guide and install rear fender. See 2.34 FEND-
ERS.
7. Bleed brakes. See BLEEDING BRAKES in 1.6 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)
8. Install negative battery cable and tighten to 72-96 in-lbs
(8-11 Nm). See 1.4 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)
9. Install seat. See 2.43 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)
10. 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)
11. Test ride motorcycle and check for proper brake opera-
tion.
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