Name: Buell 2007 LIGHTNING
Brand: Buell
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2007 Buell Lightning: Chassis 2-29

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ASSEMBLY

Front Master Cylinder

1. Obtain PISTON ASSEMBLY KIT.

2. See Figure 2-39. Assemble new piston components

placing small end of spring (5) behind primary seal of

piston (4).

3. Lubricate master cylinder body and piston seals with

special lubricant found in the service parts kit.

11WARNING1WARNING

When installing circlip to secure master cylinder, be sure

the circlip snaps into place. Failure to do so can result in

improper brake operation which could result in death or

serious injury.

4. See Figure 2-37. Insert piston assembly (6), spring ﬁrst,

into master cylinder reservoir (4).

5. See Figure 2-38. Secure piston assembly (1) with a new

circlip (2).

6. See Figure 2-39. Install ridge on boot (1) into groove on

piston (3).

Brake Hand Lever

1. See Figure 2-37. Lubricate pivot bolt (16) with LOCTITE

ANTI-SEIZE.

2. Align hole in hand lever (8) with hole in hand lever pivot

and install pivot bolt (16) through top of hand lever pivot

and tighten nut to 39-48 in-lbs (4.4-5.4 Nm) on XB9SX

models only. All other models are tightened to 80-120 in-

lbs (9-13.5 Nm).

Figure 2-39. Front Master Cylinder Piston Assembly

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1. Ridge on rubber boot

2. Circlip

3. Groove on piston

4. Primary seal of piston

5. Spring

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Buell 2007 LIGHTNING Specifications

General