2-28 2007 Buell Lightning: Chassis
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DISASSEMBLY
Brake Hand Lever
1. See Figure 2-37. Remove pivot bolt nut (9) (metric) and
pivot bolt (16) from hand lever pivot.
2. Detach front brake hand lever assembly (8) from hand
lever pivot.
3. Detach front brake lamp switch (11) by removing the
switch fastener (10).
Front Master Cylinder
1. See Figure 2-37. Remove master cylinder cover (2) by
removing cylinder cover fasteners (1).
2. Discard excess brake fluid.
3. Remove rubber boot (7) and discard.
4. See Figure 2-38. Depress piston assembly (1) and
remove internal circlip (2) and discard.
5. See Figure 2-37. Remove piston assembly (6) from front
master cylinder reservoir (4) and discard.
CLEANING AND INSPECTION
11WARNING1WARNING
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral-based solvents (such as gaso-
line or paint thinner), which will deteriorate rubber parts
even after assembly. Deterioration of these components
can cause brake failure, which could result in death or
serious injury. (00291a)
1. Clean all parts with denatured alcohol or D.O.T. 4
BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Wipe dry with a clean, lint free cloth. Blow
out drilled passages and bore with a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages in bottom of reservoir.
2. Inspect piston bore in master cylinder housing for scor-
ing, pitting or corrosion. Replace housing if any of these
conditions are found.
3. Inspect outlet port that mates with brake line fitting. As a
critical sealing surface, replace housing if any scratches,
dents or other damage is noted.
Figure 2-38. Piston Assembly in Master Cylinder
8424
2
1. Piston assembly
2. Circlip
1
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