Buell 2004 XB9S, Service Manual, Page: 133 / 597

2-30 2004 Buell Lightning: Chassis
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INSTALLATION
CAUTION
To avoid leakage, verify that gaskets, banjo bolt, hydrau-
lic brake line and master cylinder bore are completely
clean.
1. See Figure 2-37. Connect brake line (14) to master cylin-
der (4) using two new copper washers (15) and a banjo
bolt (13) (metric). Loosely install bolt into master cylinder.
2. Route the brake line from the master cylinder to the cali-
per. See
HOSE AND WIRE ROUTING for front brake
line routing.
3. Install and tighten P-clamp on inside of lighting module.
Tighten to 36-60 in-lbs (4-7 Nm). See
2.40 WIND-
SCREEN/2.26 FRONT MODULES.
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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.
CAUTION
To avoid leakage, verify that gaskets, banjo bolt, hydrau-
lic brake line and caliper bore are completely clean.
4. Install brake line to caliper.
a. See Figure 2-43. Install new copper washer, brake
line (2), new copper washer and wire form (3) onto
banjo bolt (5).
b. Finger tighten banjo bolt (5) onto front caliper being
careful not to pinch wire form (3) while tightening,
wire form should rotate around banjo bolt freely.
c. Twist brake line (2) into wire form (3) spiral and clock
wire form against bleeder valve (4).
5. Install and tighten p-clamp with fastener (1) on lower tri-
ple clamp to 36-60 in-lbs (4-7 Nm).
6. See Figure 2-37. Tighten master cylinder banjo bolt (13)
(metric) to 16-20 ft-lbs (22-27 Nm).
7. See Figure 2-43. Tighten brake caliper banjo bolt (5)
(metric) to 16-20 ft-lbs (22-27 Nm).
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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 mechanic.
8. Install bleeder valve if removed. Refill master cylinder
and bleed brakes. See
1.7 BRAKE SYSTEM MAINTE-
NANCE .
9. Pump lever to raise pressure to operating level.
1 1
WARNING
1
WARNING
Check for proper brake lamp operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper brake lamp operation could
result in death or serious injury.
10. Turn ignition key switch to ON. Apply brake hand lever to
test brake lamp operation. Turn ignition key switch to
OFF.
Figure 2-43. Front Brake Line
8429a
1. P-clamp
2. Brake line
3. Wire form
4. Bleeder valve
5. Banjo bolt
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2
3
4
5