Buell 2009 XB Series Service Manual page 125

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Figure 2-48. Removing Pistons
Clean and Inspect
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTE
Do not contaminate with mineral oil or other solvents.
1. Clean all parts with denatured alcohol or D.O.T. 4 brake
fluid.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
2. Blow out drilled passages and bore with a clean air supply.
3. Wipe dry with a clean, lint free cloth.
4. Carefully inspect all components. Replace any parts that
appear damaged or worn. Do not hone caliper piston bore.
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
5. Measure and inspect brake pads and rotor. Replace as
required. See 1.7 BRAKE SYSTEM
Assembly
1. See Figure 2-49. Lubricate new o-rings (6), pistons (7)
and caliper piston bores with D.O.T. 4 BRAKE FLUID.
2. Install two new o-rings in grooves of each piston bore.
3. Install pistons in each piston bore.
4. Install new o-rings (10) between caliper halves.
5. Clamp caliper together with caliper fasteners (2) and
tighten to 18-22 ft-lbs (24.5-29.4 Nm).
6. Install two new stopper o-rings on the pin hangers.
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Figure 2-49. Intake Flange Gasket
2009 XB Service: Chassis 2-47
MAINTENANCE.