Buell 2004 XB9S, Service Manual

Page: 130 / 597

2004 Buell Lightning: Chassis 2-27
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ASSEMBLY
Front Master Cylinder
1. Obtain PISTON ASSEMBLY KIT.
2. See Figure 2-39. Assemble new piston components
placing small end of spring (5) behind primary seal of
piston (4).
3. Lubricate master cylinder body and piston seals with
special lubricant found in the service parts kit.
1 1
WARNING
1
WARNING
When installing circlip to secure master cylinder, be sure
the circlip snaps into place. Failure to do so can result in
improper brake operation which could result in death or
serious injury.
4. See Figure 2-37. Insert piston assembly (6), spring first,
into master cylinder reservoir (4).
5. See Figure 2-38. Secure piston assembly (1) with a new
circlip (2).
6. See Figure 2-39. Install ridge on boot (1) into groove on
piston (3).
Brake Hand Lever
1. See Figure 2-37. Lubricate pivot bolt (16) with LOCTITE
ANTI-SEIZE.
2. Align hole in hand lever (8) with hole in hand lever pivot
and install pivot bolt (16) through top of hand lever pivot
and tighten nut to 80-120 in-lbs (9-14 Nm).
Figure 2-39. Front Master Cylinder Piston Assembly
b0977x2x
1. Ridge on rubber boot
2. Circlip
3. Groove on piston
4. Primary seal of piston
5. Spring
1
2
5
4
3