Buell 2002 X1, Service Manual

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2-18 2002 Buell X1: Chassis
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BRAKES 2.9
GENERAL
The front and rear brake systems use D.O.T. 4 BRAKE
FLUID and D.O.T. 4 compatible banjo washers and rear
brake lines.
●
D.O.T. 4 compatible banjo washers are black in color.
●
D.O.T. 4 compatible rear brake lines have an olive drab
coating on the metal portion of the line.
The front and rear brakes are fully hydraulic disc brake sys-
tems that require little maintenance. The front brake master
cylinder is an integral part of the brake hand lever assembly.
The rear brake master cylinder is located on the right side of
the motorcycle near the brake pedal.
Check the master cylinder reservoirs for proper fluid levels
after the first 500 miles (800 km) and every 5000 miles
(8000 km) thereafter. Also inspect fluid levels at the end of
every riding season. See
1.7 BRAKES .
Check brake pads and rotors for wear at every service inter-
val. See
1.8 BRAKE PADS AND ROTORS .
Replace D.O.T. 4 BRAKE FLUID :
●
Every 2 years.
Inspect front and rear brake lines and replace as required:
●
Every 4 years.
Inspect front and rear caliper and master cylinder seals and
replace as required:
●
Every 2 years.
If determining probable causes of poor brake operation, see
Table 2-5.
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WARNING
1
WARNING
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 1
WARNING
1
WARNING
Always test motorcycle brakes at low speed after servic-
ing or bleeding system. To prevent death or serious
injury, Buell recommends that all brake repairs be per-
formed by a Buell dealer or other qualified technician.
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WARNING
1
WARNING
D.O.T. 4 brake fluid can cause irritation of eyes and skin,
and may be harmful if swallowed. If large amount of fluid
is swallowed, induce vomiting by administering two
tablespoons of salt in a glass of warm water. Call a doc-
tor. In case of contact with skin or eyes, flush with plenty
of water. Get medical attention for eyes. KEEP BRAKE
FLUID OUT OF THE REACH OF CHILDREN. Failure to
comply could result in death or serious injury.
1 1
WARNING
1
WARNING
Never mix D.O.T. 4 with other brake fluids (such as D.O.T.
5). Use only D.O.T. 4 brake fluid in motorcycles that spec-
ify D.O.T. 4 fluid on the reservoir cap. Mixing different
types of fluid may adversely affect braking ability and
lead to brake failure which could result in death or seri-
ous injury.
1 1
WARNING
1
WARNING
Use only fresh, uncontaminated D.O.T. 4 fluid. Cans of
fluid that have been opened may have been contami-
nated by moisture in the air or dirt. Use of contaminated
brake fluid may adversely affect braking ability and lead
to brake failure which could result in death or serious
injury.
1 1
WARNING
1
WARNING
If rear brake line must be replaced, use only the brake
line with the olive drab coating on the metal portion of
the line (See Parts Catalog for Part No.) with DOT 4 brake
systems. The previous black metal brake line is NOT
compatible with DOT 4 brake fluid. 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
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
Cover molded-in-color surfaces and right handlebar
switches and use care when removing brake reservoir
cover and adding D.O.T. 4 brake fluid. Spilling D.O.T. 4
brake fluid on molded-in-color surfaces will result in cos-
metic damage. Spilling brake fluid on switches may ren-
der them inoperative.