buell s1 lightning '97 Manual
2-19
FRONT BRAKE MASTER CYLINDER
REMOVAL
NOTE
The front master cylinder contains no user serviceable parts.
Do not remove the master cylinder unless problems are being
experienced. Replace the entire assembly when necessary.
Do not remove the master cylinder unless problems are being
experienced. Replace the entire assembly when necessary.
1.
Remove mirror mounting hardware (metric, left hand
threads).
threads).
2.
Open bleeder nipple cap on front caliper. Install end of a
length of plastic tubing over caliper bleeder valve, while
placing free end in a suitable container. Open bleeder
valve about 1/2-turn. Pump brake hand lever to drain
brake fluid.
length of plastic tubing over caliper bleeder valve, while
placing free end in a suitable container. Open bleeder
valve about 1/2-turn. Pump brake hand lever to drain
brake fluid.
3.
See
Remove banjo bolt (6) (metric) and two
gaskets (4) to disconnect brake line from master cylinder.
Discard gaskets.
Discard gaskets.
4.
Remove screw (10), lockwasher (9) and washer (8) to
detach brake lamp switch (7).
detach brake lamp switch (7).
NOTE
The individual parts of the brake lamp switch are not service-
able. Replace switch upon failure.
able. Replace switch upon failure.
5.
Remove two screws (1) (metric) and clamp to free mas-
ter cylinder assembly from handlebar.
ter cylinder assembly from handlebar.
INSTALLATION
1.
See
Fasten master cylinder to handlebar by
installing clamp (2) and screws (1) (metric). Tighten
screws to 80-90 in-lbs (9.0-10.2 Nm).
screws to 80-90 in-lbs (9.0-10.2 Nm).
1
CAUTION
To avoid leakage, verify that gaskets, banjo bolt, hydrau-
lic brake line and master cylinder bore are completely
clean.
lic brake line and master cylinder bore are completely
clean.
2.
Place new gaskets on each side of the hydraulic brake
line. Install banjo bolt through gaskets and brake line fit-
ting into master cylinder. Tighten banjo bolt (6) (metric) to
17-20 ft-lbs (23.0-27.1 Nm).
line. Install banjo bolt through gaskets and brake line fit-
ting into master cylinder. Tighten banjo bolt (6) (metric) to
17-20 ft-lbs (23.0-27.1 Nm).
3.
Attach brake lamp switch (7) with screw (10), lockwasher
(9) and washer (8).
(9) and washer (8).
4.
Remove both master cylinder cover screws (3) and cover.
5.
With the master cylinder in a level position, add D.O.T. 5
SILICONE HYDRAULIC BRAKE FLUID. Bring fluid level
to within 1/8 in. (3.2 mm) of molded boss inside front mas-
ter cylinder reservoir.
SILICONE HYDRAULIC BRAKE FLUID. Bring fluid level
to within 1/8 in. (3.2 mm) of molded boss inside front mas-
ter cylinder reservoir.
1
WARNING
A plugged or covered relief port can cause brake drag or
lockup, which may result in loss of vehicle control and
possible personal injury.
lockup, which may result in loss of vehicle control and
possible personal injury.
6.
Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
components are working properly.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
components are working properly.
7.
Install master cylinder cover screws (3) and cover.
Tighten cover screws to 9-13 in-lbs (1.0-1.5 Nm).
Tighten cover screws to 9-13 in-lbs (1.0-1.5 Nm).
8.
Bleed brake system. See
BRAKES
in Section 1.
9.
Install mirror parallel to handlebars. Mirror mount has
metric, left hand threads.
metric, left hand threads.
10. Test brake lamp operation with the brake hand lever
applied and the ignition/headlamp switch turned to IGN.
Figure 2-18. Front Master Cylinder Banjo Bolt
1.
Clamp screws (2)
(metric)
(metric)
2.
Clamp
3.
Master cylinder
cover screws (2)
cover screws (2)
4.
Gaskets (2)
5.
Brake line
6.
Banjo bolt (metric)
7.
Front brake lamp
switch
switch
8.
Washer
9.
Lockwasher
10. Screw
b0203a2x
1
3
4
2
5
6
7
8
10
9