Buell 2002 S3T, Service Manual

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2-20 2002 Buell S3T: Chassis
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INSTALLATION
1. See Figure 2-18. Fasten master cylinder to handlebar by
installing clamp (2) and screws (1) (metric). Tighten to
80-90
in-lbs (9-10 Nm).
1 1
WARNING
1
WARNING
Use only copper crush 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.
1 1
WARNING
1
WARNING
Any leak in brake system will adversely affect brake
operation. To avoid leakage after assembly, verify that
gaskets, banjo bolt, hydraulic brake line and bore of
master cylinder are completely clean. Failure to comply
could result in death or serious injury.
2. Connect brake line (5) to master cylinder using two new
banjo washers (4) and banjo bolt (6) (metric). Tighten to
16-20 ft-lbs (22-27 Nm).
3. Attach brake lamp switch (7) with screw (10), lockwasher
(9) and washer (8).
4. Remove two master cylinder cover screws (3), cover and
cover gasket.
5. See Figure 2-25. With the master cylinder in a level posi-
tion, add D.O.T. 4 BRAKE FLUID . Bring fluid level to
within 1/8 in. (3.2 mm) of molded boss inside front master
cylinder reservoir.
1 1
WARNING
1
WARNING
Always verify proper operation of relief port (see Step 6).
A plugged or covered relief port can cause brake drag or
lockup, which may cause loss of vehicle control which
could result in death or serious 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.
7. Attach master cylinder cover, cover gasket and plastic
insert with two cover screws. Tighten to 9-13
in-lbs (1-2
Nm).
8. Bleed brake system. See 1.5 BRAKES .
1 1
WARNING
1
WARNING
Check for proper brake lamp operation before riding
motorcycle (see Step 9). Visibility is a major concern for
motorcyclists. Failure to have proper brake lamp opera-
tion could result in death or serious injury.
9. Turn ignition key switch to IGN. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
OFF.
Figure 2-22. Piston Assembly
Figure 2-23. Master Cylinder Body
Figure 2-24. Testing Hand Lever
6491
1. Spring
2. Primary Cup
3. Secondary Cup
4. Piston
5. Boot
6. Snap Ring
1
2
3
4
6
5
Outlet Port
6492
6493
1. Screw, Lockwasher and Washer
2. Tang
3. Hand Lever
1
2
3