Rear Brake Caliper - Buell 2002 X1 Handbook

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REAR BRAKE CALIPER

REMOVAL
NOTE
Steps 1 and 2 are not required for detaching caliper from
rotor. Drain fluid only when disassembling caliper.
1. Drain and discard brake fluid. See Step 1 (Removal) in
2.13 REAR BRAKE MASTER
CAUTION
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
2. See Figure 2-44. Remove banjo bolt (2) (metric) and two
banjo washers (3) to disconnect brake line (1) from cali-
per. Discard banjo washers.
3. Remove small screw (6) (metric) and large screw (7)
(metric) to detach caliper from mount.
4. See Figure 2-45. Remove clip (1) from rear caliper
mount (2) if necessary.
DISASSEMBLY
1. See Figure 2-44. Remove pin plug and pad hanger (5)
(metric) to free brake pads.
2. See Figure 2-46. Remove clip (1) from caliper body.
3. See Figure 2-47. Remove piston (3) using BRAKE CALI-
PER PISTON REMOVER (1) (Part No. B-42887) with
adaptor (2).
4. Remove two O-rings from groove in caliper bore. Discard
O-rings.
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 may 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.
2002 Buell X1: Chassis
CYLINDER.
WARNING
7036
3
2
1
7
1. Brake Line
2. Banjo Bolt (metric)
3. Banjo Washers (2)
4. Bleeder Valve (metric)
5. Pin Plug and Pad Hanger (metric)
6. Small Screw (metric)
7. Large Screw (metric)
Figure 2-44. Rear Brake Caliper
6486
2
1. Clip
2. Rear Caliper Mount
Figure 2-45. Caliper Mount Clip
2. Carefully inspect all components. Replace any parts that
appear damaged or worn. Do not hone caliper piston
bore.
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.
3. Inspect brake rotor and pads. See
AND ROTORS.
2.14
4
5
6
1
WARNING
1.8 BRAKE PADS
2-31