Buell 2005 P3, Service Manual, Page: 125 / 426

2-26 2005 Buell P3: Chassis
HOME
INSTALLATION
1. See Figure 2-27. Fasten master cylinder to handlebar by
installing clamp (2) and screws (1) (metric). Tighten to
80-120 in-lbs (9-14 Nm).
1 1
WARNING
1
WARNING
● Use only new black banjo washers (See Parts Cata-
log for Part No.) with D.O.T. 4 brake fluid. Earlier sil-
ver 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 seri-
ous injury.
● Avoid leakage. Be sure gaskets, banjo bolt(s), brake
line and master cylinder bore are clean and undam-
aged before assembly. (00322a)
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. See Figure 2-35. Verify brake lamp switches are secure.
Attach wires to switches.
4. Install mirror parallel to handlebars.
5. See Figure 2-27. Remove the two master cylinder cover
screws (3), cover and cover gasket.
6. See Figure 2-36. With the master cylinder in a level posi-
tion, add D.O.T. 4 BRAKE FLUID. Bring fluid level to
within 0.125 in. (3.2 mm) of molded boss inside front
master cylinder reservoir.
1 1
WARNING
1
WARNING
Verify proper operation of the master cylinder relief port.
A plugged or covered relief port can cause brake drag or
lockup, which could result in loss of vehicle control and
death or serious injury
7. See Figure 2-36. Verify proper operation of the master
cylinder relief port.
8. 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.
9. See Figure 2-27. Attach master cylinder cover and cover
gasket with the two cover screws (3). Tighten to 9-13 in-
lbs (1.0-1.5 Nm).
10. Bleed brake system. See 1.7 BRAKE SYSTEM MAINTE-
NANCE.
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.
11. Turn ignition key switch to IGN. Apply brake hand lever to
test brake lamp operation. Turn ignition switch to LOCK.
1 1
WARNING
1
WARNING
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
high speeds can cause loss of control, which could
result in death or serious injury. (00289a)
Figure 2-35. Brake Lamp Switch Connectors
6569
Figure 2-36. Brake Fluid Level
a0214x2x