Buell 2002 X1 Handbook page 79

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ASSEMBLY
1. See Figure 2-46. 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. See Figure 2-47. 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 (3) inside caliper body.
3. See Figure 2-46. Install brake pads (3) using pad hanger
and pin plug (2).
a. Install pad hanger pin (metric). Tighten to 11-14.5 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).
INSTALLATION
1. See Figure 2-45. Install caliper mount clip (1) if removed.
2. See Figure 2-44. Install caliper assembly on caliper
mount. Brake pad surfaces must face rear brake rotor.
a. Apply LOCTITE THREADLOCKER 272 (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
14.5-18 ft-lbs (20-24 Nm).
2-32
6487
1
2
1. Clip
2. Pin Plug and Pad Hanger (metric)
3. Brake Pads (2)
Figure 2-46. Brake Pads
6496
1
1. Brake Caliper Piston Remover
2. Adaptor
3. Piston
Figure 2-47. Removing Rear Brake Caliper Piston
3
2
3
2002 Buell X1: Chassis