Buell XB 2008 Series, Service Manual

Page: 117 / 688

NOTE
Tighten the right side banjo bolt with FLARE NUT
SOCKET (Part No. SNAP-ON FRXM14) or a crowsfoot.
2. Install brake line, banjo bolt and new copper washers to
rear caliper. Tighten to 16-20 ft-lbs (22-27 Nm).
3. See Figure 2-59 . Secure brake line (1) to left side of
swingarm with p-clamp (2), and tighten to 36-60 in-lbs (4-
7 Nm). See
D.1 APPENDIX D: HOSE AND WIRE
ROUTING for brake line routing.
4. See Figure 2-58 . Connect brake light switch connector
beneath seat.
5. Install rear inner fender. Ensure that brake line is correctly
captured by rear fender. See
2.15 FENDERS .
6. Install right heel guard. See 2.36 FOOTPEG, HEEL
GUARD AND MOUNT: FIREBOLT/LIGHTNING .
7. Bleed brakes. See 1.6 BRAKE SYSTEM MAINTENANCE,
Bleeding Brakes .
8. Install negative battery cable and tighten to 72-96 in-
lbs (8-11 Nm). See
1.4 BATTERY MAINTENANCE .
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
9. Install seat.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
10. Turn ignition key ON, depress rear brake pedal and check
for proper brake light operation.
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
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)
11. Test ride motorcycle and check for proper brake operation.
REMOVAL: LIGHTNING
1. Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery by unthreading fastener removing
negative cable (black) from battery first. See
1.4 BATTERY
MAINTENANCE .
3. See Figure 2-61 . Disconnect brake light connector from
under seat in the front of the battery.
4. Remove right side heel guard. See 2.36 FOOTPEG, HEEL
GUARD AND MOUNT: FIREBOLT/LIGHTNING .
5. Drain brake fluid into a suitable container. Discard used
fluid according to local laws.
a. Install a length of plastic tubing over caliper bleeder
valve. Place free end in a suitable container.
b. Open bleeder valve (metric) about 1/2-turn.
c. Pump brake foot pedal to drain brake fluid.
d. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm).
6. Remove rear fender. See 2.15 FENDERS .
NOTE
All models except for the XB12Ss, XB12STT, XB12XT and the
XB12X use a p-clamp to secure the rear brake line to the
swingarm. The XB12Ss, XB12STT and the XB12X utilizes the
rear fender to capture and secure the rear brake line.
7. See Figure 2-60 . Remove p-clamp (2) securing brake line
(1) to the left side of swingarm.
Remove brake line components carefully. Damage to
seating surfaces can cause leakage. (00320a)
8. Remove banjo bolt (3) from rear caliper. Discard copper
washers.
9. See Figure 2-60 . Remove brake line switch/banjo bolt from
rear master cylinder. Discard copper washer.
10. Remove brake line from motorcycle.
sm00543
Figure 2-61. Brake Line Switch Connector (XB12S Shown)
INSTALLATION: LIGHTNING
TOOL NAME PART NUMBER
FLARE NUT SOCKET SNAP-ON FRXB14
1. See Figure 2-60 . Install brake light switch/banjo bolt with
new copper washers to the master cylinder. Tighten to
16-20 ft-lbs (22-27 Nm).
2008 XB Service: Chassis 2-41