Assembly - Buell XB 2008 Series Service Manual

2. 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)
3. Inspect brake rotor and pads. See
MAINTENANCE.
4. Check rotor surface. Replace if warped or badly scored.
Refer to Table 2-17.
Table 2-17. Front Rotor Runout
RUNOUT
Radial
Lateral

ASSEMBLY

1. See Figure 2-44. Install pistons and o-rings.
a. Lubricate new o-rings (6), pistons (5), and caliper
piston bores with D.O.T. 4 BRAKE FLUID.
b. Install two new o-rings (6) in grooves of each piston
bore.
c. Install pistons (5) in each piston bore.
2. Install new o-rings (8) between caliper halves.
3. Clamp caliper together with caliper fasteners (11) and
tighten to 15-19 ft-lbs (20-26 Nm).
1.6 BRAKE SYSTEM
IN. MM
0.0177 0.45
0.0248 0.63
INSTALLATION
1. See Figure 2-44. Install pad spring (7) and brake pads
(10).
2. Install pin hanger set (1) and tighten to 11-14 ft-lbs (15-19
Nm).
3. Slide the caliper over the rotor up to the mount and install
caliper on caliper mount. Using LOCTITE 271 (red).
Tighten caliper mounting fasteners (9) to 35-37 ft-lbs (47-
50 Nm).
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)
4. Install brake line to caliper. See
5. Bleed front brakes. See
ANCE, Bleeding Brakes.
6. On Ulysses models, install lower right fender. See
2.15 FENDERS.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
7. Turn ignition key switch to ON. Apply brake hand lever to
test brake lamp operation.
2008 XB Service: Chassis 2-31
2.9 FRONT BRAKE LINE.
1.6 BRAKE SYSTEM MAINTEN-