Buell S1 Lightning, Workshop Manual

Page: 102 / 371

2-24
ASSEMBLY/INSTALLATION
1. See Figure 2-24. Mount reservoir assembly on frame
with screw. Tighten screw to 12-15 in-lbs (1.4-1.7 Nm).
Clamp reservoir hose to rear master cylinder with a new
clamp and
HOSE CLAMP PLIERS (Part No. HD-41137) .
2. Attach rear master cylinder to frame with two screws and
locknuts. Tighten to 8-10 ft-lbs (10.8-13.6 Nm).
1
CAUTION
To avoid leakage after assembly, verify that gaskets,
banjo bolt, rear brake line and bore of master cylinder are
completely clean.
3. Position new gaskets on each side of rear brake line at
master cylinder. Insert banjo bolt (metric) through gas-
kets and brake line. Thread banjo bolt (metric) into rear
brake master cylinder and tighten to 10-12 ft-lbs (13.6-
16.2 Nm).
4. See Figure 2-23. Place push rod into rear master cylinder.
Install male rod end behind brake pedal with screw and
locknut. Tighten screw to 10-12 ft-lbs (13.6-16.2 Nm).
5. Adjust brake pedal freeplay.
6. See Figure 2-25. With the master cylinder in a level posi-
tion, check that the brake fluid level is between the upper
and lower marks on reservoir. Add D.O.T. 5 SILICONE
HYDRAULIC BRAKE FLUID if necessary. Be sure cap is
securely screwed on.
1
WARNING
A plugged or covered relief port can cause brake drag or
lockup, which may result in loss of vehicle control and
possible personal injury.
7. Bleed brake system. See BRAKES in Section 1.
8. Test brake lamp operation with the rear brake pedal
applied and the ignition/headlamp switch turned to IGN.
Figure 2-25. Proper Rear Brake Fluid Level
5559
Upper mark
Lower mark