Buell X1 2002 - Page 97

2002 Buell X1: Chassis 2-29
HOME
CLEANING AND INSPECTION
11WARNING1WARNING
Clean brake system components using denatured alco-
hol. Do not use mineral-base cleaning solvents, such as
gasoline or paint thinner. Use of mineral-base solvents
causes deterioration of rubber parts that continues after
assembly. This may result in improper brake operation
which could result in death or serious injury.
1. Thoroughly clean master cylinder and all brake system
components. Stand master cylinder on wooden block or
towel to protect seating surfaces.
a. Examine walls of master cylinder reservoir for
scratches and grooves. Replace if damaged.
b. Ver ify that vent holes on master cylinder are com-
pletely open and free of dirt or debris.
2. Inspect boot on front of master cylinder for cuts, tears or
general deterioration. Replace if necessary.
ASSEMBLY
1. See
Figure 2-43. Insert piston assembly (4), spring first,
into master cylinder.
2. Place round side of rod assembly (3) over piston.
Depress piston into master cylinder body (1) and secure
with a new snap ring (2).
3. Tuck rubber boot on rod assembly (3) into master cylin-
der body (1).
INSTALLATION
1. See
Figure 2-42. Connect remote reservoir.
a. If removed, attach remote reservoir to frame using
screw. Tighten to 12-15 in-lbs (1.4-1.7 Nm).
b. Attach line to master cylinder using clamp.
2. See
Figure 2-41. Attach master cylinder (3) to frame.
Apply LOCTITE THREADLOCKER 243 (blue) to both
screws (2) (metric). Tighten to 8-10 ft-lbs (11-14 Nm).
11WARNING1WARNING
Use only new black 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.
3. See Figure 2-39. Connect brake line (3) to master cylin-
der (4) with two new banjo washers (2) and banjo bolt (1)
(metric). Tighten to 16-20 ft-lbs (22-27 Nm).
Figure 2-40. Brake Push Rod
Figure 2-41. Master Cylinder Mounting
b0470x1x
1. Rubber Boot
2. Rod Adjuster
3. Locknut
4. Top Surface of Turn Buckle
1
2
3
4
7085
1
3
1. Banjo Bolt (metric)
2. Screw (2) (metric)
3. Master Cylinder Body
4. Clamp
5. Remote Reservoir Hose
5
4
2