Buell 2002 P3 Service Manual page 107

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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 0.18 in. (4.5 mm).
b. Check rotor surface. Replace if warped or badly
scored.
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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 0.04 in. (1.0 mm) or less.
ASSEMBLY
1. See Figure 2-50. Place clip (1) inside caliper body as
shown.
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 2-50. Install brake pads (3) using pad hanger
and pin plug (2).
a. Install pad hanger pin (metric). Tighten to 11-15 ft-
lbs (15-20 Nm).
b. Install pin plug. Tighten to 1.5-2.1 ft-lbs (2-3 Nm).
4. Install a new bleeder valve (metric) if necessary. Tighten
to 3-5 ft-lbs (4-7 Nm).
2-32 2002 Buell P3: Chassis
WARNING
WARNING
INSTALLATION
1. See Figure 2-48. Install caliper mount clip (1) if removed.
2. See Figure 2-47. Install caliper assembly on caliper
mount. Brake pad surfaces must face rear brake rotor.
a. Apply LOCTITE THREADLOCKER 271 (red) to both
caliper mounting screws (6, 7) (metric).
b. Install large caliper screw (7) (metric). Tighten to 18-
22 ft-lbs (24-30 Nm)
c. Install small caliper screw (6) (metric). Tighten to 15-
18 ft-lbs (20-24 Nm).
11 1
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.
3. 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).
4. Depress rear brake pedal several times to set brake
pads to proper operating position within caliper. Bleed
brake system.
5. Verify proper fluid level in reservoir.
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.
6. Turn ignition key switch to IGN. Apply brake pedal 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. To prevent death or serious
injury, Buell strongly recommends that all brake repairs
be performed by a Buell dealer or other qualified techni-
cian.
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to "wear in" properly with the brake rot.
WARNING
WARNING
WARNING