Buell XB 2008 Series, Service Manual

Page: 38 / 688

1.6 BRAKE SYSTEM MAINTENANCE
GENERAL
Check brake fluid level and condition:
• When storing or removing the motorcycle for the season.
Replace D.O.T. 4 BRAKE FLUID:
• Every 2 years.
Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
described.
Inspect front and rear brake lines and replace as required:
• Every 4 years.
Inspect caliper and master cylinder seals and replace as
required:
• Every 2 years.
If determining probable causes of poor brake operation, refer
to
Table 1-7 .
Table 1-7. Brake Troubleshooting
REMEDY CHECK FOR CONDITION
Bleed brake(s). Air in system. Excessive lever/pedal travel or spongy feel
Fill master cylinder with approved brake
fluid. Master cylinder fluid low.
Bleed brake(s). Moisture in system. Brake fade
Replace fluid in master cylinder with
approved brake fluid.
Replace brake pads. Worn pads. Chattering sound when brake is applied
Replace rotor and bushings as a set. Worn D shape bushings.
Tighten bolts. Loose mounting bolts.
Replace rotor and bushings as a set. Warped rotor.
Fill master cylinder with approved brake
fluid. Low fluid level.
Piston cup not functioning. Ineffective brake, lever/pedal travels to
limit
Rebuild cylinder.
Replace rotor and bushings as a set. Distored or glazed rotor. Ineffective brake, lever/pedal travel normal
Replace brake pads. Distorted, glazed or contaminated brake
pads.
Inspect master cylinder. Cup in master cylinder not uncovering
relief port. Brake pads drag on rotor, will not retract
Adjust brake pedal linkage.
Rear brake pedal linkage out of adjust-
ment.
BLEEDING BRAKES
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)
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)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTE
Use only new 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
1-16 2008 XB Service: Maintenance