Buell P3 2003 Service Manual page 107

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DISASSEMBLY
1. See Figure 2-39. Use BRAKE CALIPER PISTON
REMOVER (Part No. B-42887) to pull the two pistons
from caliper bores.
7699
Figure 2-39. Removing Pistons
7700
1
2
4
1. Caliper
2. Piston (2)
3. Inner seals
4. Outer seals
Figure 2-40. Caliper O-rings and Pistons
2. See Figure 2-40. Remove piston outer seals (4) and
inner seals (3) from their respective grooves in caliper.
Discard seals.
3. Check bleeder valve (metric). Remove and replace if
damaged.
2-28 2003 Buell P3: Chassis
CLEANING AND INSPECTION
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.
b.
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.
2
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
a.
3
b.
c.
d.
2. Install a new bleeder valve (metric) if necessary. Tighten
to 36-60 in-lbs (4-7 Nm).
11 1
WARNING WARNING
Measure rotor thickness. Replace if minimum thick-
ness is less than 0.18 in. (4.5 mm).
Check rotor surface. Replace if warped or badly
scored.
11 1
WARNING WARNING
Figure 2-40. Install pistons and O-rings.
Apply a light coat of D.O.T. 4 BRAKE FLUID to
seals, pistons and caliper piston bores.
Install two new seals (4) in outer grooves of each
piston bore.
Install two new seals (3) in inner grooves of each
piston bore.
Install pistons (2) in each piston bore.