Removal - Buell XB 2008 Series Service Manual

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).
Remove brake line components carefully. Damage to
seating surfaces can cause leakage. (00320a)
2. Only Ulysses models, remove fasteners on lower right
fender. See 2.15 FENDERS.
3. See Figure 2-41. Disconnect brake line (1) at caliper (2).
See 2.9 FRONT BRAKE
4. Remove caliper mounting fasteners (3).
5. Slide caliper down the rotor to clear fork lower and then
remove off rotor.
sm00534
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2
1. Brake line
2. Front brake caliper
3. Caliper mounting fasteners (2)
Figure 2-41. Front Brake Caliper Mounts (Typical)
DISASSEMBLY
PART NUMBER
B-42887 BRAKE CALIPER PISTON REMOVER
1. See Figure 2-42. Remove pin hanger set (1), brake pads
and caliper pad spring (2).
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 CAL-
IPER PISTON REMOVER (Part No. B-42887).
5. See Figure 2-44. Remove and discard piston o-rings (6).
2-30 2008 XB Service: Chassis
LINE.
3
TOOL NAME
sm00535
3
1. Pin hanger set
2. Caliper pad spring
3. Caliper fasteners (4)
4. Bleeder valve
Figure 2-42. Pad Spring (Typical)
sm00536
Figure 2-43. Removing Pistons (B-42887)
CLEANING AND INSPECTION
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)
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 passages.
2.10
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