Front Brake Caliper - Buell 2003XB9S Service Manual

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FRONT BRAKE CALIPER

REMOVAL
1. Drain brake fluid into a suitable container. Discard used
fluid according to local laws.
a. Install a length of plastic tubing over caliper bleeder
valve. Place free end in a suitable container.
b. Open bleeder valve (metric) about 1/2-turn.
c. Pump brake hand lever to drain brake fluid.
d. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm).
CAUTION
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
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1. Wire form
2. Brake line
3. Banjo bolt (metric)
4. Pin plug
5. Mounting fasteners (2)
Figure 2-41. Front Brake Caliper Mounts
2. See Figure 2-41. Disconnect brake line at caliper. See
2.11 FRONT BRAKE LINE.
3. Remove caliper mounting fasteners (5).
4. Slide caliper down the rotor to clear fork lower and then
remove off rotor.
2-30 2003 Buell XB9S: Chassis
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5
DISASSEMBLY
1. See Figure 2-42. Remove pin hanger set (1), brake pads
and caliper pad spring (2).
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1. Pin hanger set
2. Caliper pad spring
3. Caliper fasteners
Figure 2-42. Pad Spring (Typical)
2. Split caliper by removing caliper fasteners (3).
3. See Figure 2-44. Remove and discard o-rings (8).
4. See Figure 2-43. Remove pistons using a BRAKE PIS-
TON REMOVER (Part No. B-42887).
5. See Figure 2-44. Remove and discard top and bottom
piston o-rings (6).
6495
Figure 2-43. Removing Pistons (B-42887)
2.12
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