Buell Blast 2014 Service Manual page 117

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CLEANING AND INSPECTION
11 1
WARNING
Clean brake system components using denatured alco-
hol. Do not use mineral-base cleaning solvents, such as
gasoline or paint thinner. Use of mineral-base solvents
causes deterioration of rubber parts that continues after
assembly. This could result in improper brake operation
which could result in death or serious injury.
1. Clean all parts with denatured alcohol or D.O.T. 4
BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Wipe dry with a clean, lint free cloth. Blow
out drilled passages and bore with a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages.
2. Carefully inspect all components. Replace any parts that
appear damaged or worn. Do not hone caliper piston
bore.
3. Inspect brake rotor.
a. Measure rotor thickness. Replace if minimum thick-
ness is less than 0.180 in. (4.5 mm).
b. Check rotor surface. Replace if warped or badly
scored.
11 1
WARNING
Always replace brake pads in complete sets for correct
brake operation. Never replace just one brake pad. Fail-
ure to install brake pads as a set could result in death or
serious injury.
4. Inspect brake pads for damage or excessive wear.
Replace both pads as a set if the friction material of
either pad is worn to 0.040 in. (1.0 mm) or less.
2-38 2004 Buell P3: Chassis
WARNING
WARNING
ASSEMBLY
1. See Figure 2-57. Place clip (1) inside caliper body as
shown.
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1. Clip
2. Pin plug and pad hanger (metric)
3. Brake pads (2)
Figure 2-57. Brake Pads
NOTE
To ensure proper brake pad-to-brake rotor clearance when
the caliper is installed, piston must be pressed all the way into
the bore whenever new brake pads are used.
2. Install pistons and o-rings.
a. Apply a light coat of D.O.T. 4 BRAKE FLUID to o-
rings, piston and caliper piston bore.
b. Place two new o-rings inside grooves of piston bore.
c. Install piston inside caliper body.
3. See Figure 2-57. Install brake pads (3) using pad hanger
and pin plug (2).
a. Install pad hanger pin (metric). Tighten to 132-180
in-lbs (15-20 Nm).
b. Install pin plug. Tighten to 18-25 in-lbs (2-3 Nm).
4. Install a new bleeder valve (metric) if necessary. Tighten
to 36-60 in-lbs (4-7 Nm).
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