Buell 2002 P3 Service Manual page 101

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INSTALLATION
1. Fit front brake caliper on rotor.
a. Slide carrier on caliper.
b. Slide caliper over front brake rotor without brake
pads installed.
2. See Figure 2-36. Apply LOCTITE THREADLOCKER 272
(red) to both caliper mounting screws (5). Install wireform
to upper screw and tighten both screws to 18-22 ft-lbs
(24-30 Nm).
3. Install brake pads.
a. See Figure 2-37. Install pad spring (2) with opening
at top as shown.
b. Insert inboard brake pad from rear of caliper.
c. Insert outboard pad.
d. See Figure 2-37. Install pad hanger pin (1) (metric).
Tighten to 11-15 ft-lbs (15-20 Nm).
e. See Figure 2-36. Install pin plug (4). Tighten to 1.5-
2.1 ft-lbs (2-3 Nm).
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WARNING
Use only new black 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 braking ability and lead to brake failure
which could result in death or serious injury.
CAUTION
To avoid leakage, verify that banjo washers, banjo bolt,
hydraulic brake line and caliper bore are completely
clean.
4. Connect brake line (1) to caliper using two new banjo
washers (3) and banjo bolt (2) (metric). Tighten to 16-20
ft-lbs (22-27 Nm).
5. Route brake line through wireform.
CAUTION
Cover molded-in-color surfaces and right handlebar
switches and use care when removing brake reservoir
cover and adding D.O.T. 4 brake fluid. Spilling D.O.T. 4
brake fluid on molded-in-color surfaces will result in cos-
metic damage. Spilling brake fluid on switches may ren-
der them inoperative.
6. See Figure 2-40. Remove both master cylinder cover
screws (2). Remove master cylinder cover (1) and gasket.
7. With the master cylinder in a level position, verify that the
brake fluid level is 0.125 in. (3.2 mm) from molded boss
inside reservoir. Add D.O.T. 4 BRAKE FLUID if neces-
sary.
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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
2-26 2002 Buell P3: Chassis
WARNING
WARNING
8. Verify proper operation of the master cylinder relief port.
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. Install master cylinder cover (1) and cover gasket with
two screws (2). Tighten to 9-13 in-lbs (1.0-1.5 Nm).
10. Depress front brake lever several times to set brake pads
to proper operating position within caliper. Bleed brake
system.
11 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 key switch to
LOCK.
11 1
WARNING
Always test motorcycle brakes at low speed after servic-
ing or bleeding system. If brakes are not operating prop-
erly, or braking efficiency is poor, testing at high speeds
could result in death or serious injury.
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to "wear in" properly with the brake
rotor.
7024
2
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1. Master Cylinder Cover
2. Screws (2)
Figure 2-40. Master Cylinder Cover
WARNING
WARNING
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