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2002 Buell X1: Chassis
2-21
HOME
CLEANING AND INSPECTION
1
1
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.
Clean all parts with denatured alcohol or
D.O.T. 4
BRAKE FLUID
. Do not contaminate with mineral oil or
other solvents. Wipe dry with a clean, lint free cloth. Blow
out drilled passages and bore with a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages in bottom of reservoir.
2.
Carefully inspect all parts for wear or damage and
replace as necessary.
3.
Inspect piston bore in master cylinder housing for scor-
ing, pitting or corrosion. Replace housing if any of these
conditions are found.
4.
Inspect outlet port that mates with brake line fitting. As a
critical sealing surface, replace housing if any scratches,
dents or other damage is noted.
5.
Inspect boot for cuts, tears or general deterioration.
Replace as necessary.
ASSEMBLY
1.
See
Figure 2-25.
Check piston assembly components.
a. Small end of spring (1) sits behind primary cup (2).
Large side of primary cup faces spring.
b.
Secondary cup (3) sits within ridge at middle of pis-
ton (4).
2.
Insert piston assembly, spring first, into master cylinder.
Secure with a
new
snap ring (6).
3.
Install ridge on boot (5) into groove on piston (4).
4.
See
Figure 2-23.
Install front brake hand lever.
a. Align hole in lever (3) with hole in master cylinder
assembly.
b.
Lubricate pivot bolt (2) with LOCTITE ANTI-SEIZE.
c. Install pivot bolt through top of assembly. Tighten to
4-13
in-lbs
(0.5-1.5 Nm).
d. Install nut (1) (metric). Tighten to 44-62
in-lbs
(5-7
Nm).
5.
See
Figure 2-22.
Install front brake lamp switch (7).
a. Attach front brake lamp switch with screw (8).
Tighten to 7-13
in-lbs
(1-2 Nm).
b.
Test switch action. Tang on switch must release
when hand lever is moved.
Figure 2-23. Hand Lever
Figure 2-24. Snap Ring
Figure 2-25. Piston Assembly
6488
2
3
1
1.
Nut (metric)
2.
Pivot Bolt
3.
Hand Lever
6490
2
1.
Boot
2.
Piston
3.
Snap Ring
3
1
6491
1.
Spring
2.
Primary Cup
3.
Secondary Cup
4.
Piston
5.
Boot
6.
Snap Ring
1
2
3
4
6
5
Summary of Contents for 2002 X1
Page 2: ...1 2 2002 Buell X1 Engine Printed July 25 2001 11 21 am ...
Page 22: ......
Page 32: ...1 10 2002 Buell X1 Maintenance HOME NOTES ...
Page 68: ......
Page 152: ...2 84 2002 Buell X1 Chassis HOME NOTES ...
Page 154: ......
Page 184: ...3 30 2002 Buell X1 Engine HOME NOTES ...
Page 216: ...3 62 2002 Buell X1 Engine HOME NOTES ...
Page 220: ...4 2 2002 Buell X1 Fuel System HOME NOTES ...
Page 336: ...4 118 2002 Buell X1 Fuel System HOME NOTES ...
Page 338: ......
Page 348: ...5 10 2002 Buell X1 Electric Starter HOME NOTES ...
Page 358: ...5 20 2002 Buell X1 Electric Starter HOME NOTES ...
Page 360: ......
Page 398: ......
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