Rear Pad Removal; Rear Pad Installation - Buell XB 2008 Series Service Manual

5. See Figure 1-18. Install pin hanger (2) making sure it
engages hole on both pads and spring clip.
6. Rotate caliper clockwise to align mounting fastener hole.
7. Install lower caliper mounting fastener (4).
8. Apply LOCTITE 271 (red) and tighten both caliper
mounting fasteners (3, 4) to 35-37 ft-lbs (48-50 Nm).
9. Tighten pin (2) to 11-14 ft-lbs (15-19 Nm).
10. Check brake fluid level and install front master cylinder
reservoir cap and tighten screws to 9-13 in-lbs (1.0-1.5
Nm).
11. On XB12X models: install right front fender.See
2.15 FENDERS.
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to "wear in" properly with the rotor.
sm00494
1
1. Rotor mounting fastener (6)
2. Front caliper pin hanger
3. Upper caliper mounting fastener (behind fender
on Ulysses)
4. Lower caliper mounting fastener
Figure 1-18. Front Brake Caliper (Typical)

Rear Pad Removal

1. See Figure 1-19. Remove rear caliper pin plug (3) and
loosen pin (4).
2. On Firebolt and Lightning models (except XB12Ss),
remove the fastener securing p-clamp and brake line
assembly to swingarm.
NOTE
XB12Ss and XB12STT models use the rear fender to secure
the brake line and not a p-clamp.
3. On XB12Ss and XB12STT models, remove rear fender.
See 2.15 FENDERS.
4. Remove two mounting fasteners (1) securing brake caliper
and carrier assembly to swingarm.
5. Lift caliper and carrier assembly up and off of rotor.
6. Remove pin hanger (4).
7. See Figure 1-20. Remove inner and outer pads, being
careful not to dislodge pad spring.
3
2
4

Rear Pad Installation

1. Remove rear master cylinder reservoir cover.
NOTE
As the pistons are pushed back into the caliper, fluid level may
rise more than 1/8 in. (3.2 mm) and overflow the reservoir.
Watch the fluid level as the pistons are retracted and remove
fluid from the reservoir if necessary.
2. See Figure 1-19. Check that retainer (2) is present.
3. See Figure 1-20. Check that pad spring is present. Should
pad spring become dislodged, install with widest area of
spring towards piston side of caliper.
4. Push piston in with suitable tool such as a clean paint
scraper until fully seated in bore.
5. Install new inner and outer brake pads.
6. See Figure 1-19. Install hanger pin (4) making sure pin
engages hole on both pads.
7. Install brake caliper and carrier assembly over rotor.
8. Install two mounting fasteners (1) through swingarm into
carrier and tighten to 24-26 ft-lbs (32.5-35 Nm).
9. Install hanger pin and tighten to 11-14 ft-lbs (14.9-18.9
Nm).
10. Install pin plug (3) and tighten pin plug to 24 in-lbs (3 Nm).
11. On Firebolt and Lightning models (except XB12Ss and
XB12STT), install fastener securing p-clamp and brake
line assembly to swingarm and tighten to 36-60 in-lbs (4.1-
6.8 Nm).
12. On XB12Ss, XB12X, XB12XT and XB12STT models,
install rear fender. See
13. Check brake fluid level and install master cylinder reservoir
cap and tighten cap securely.
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to "wear in" properly with the rotor.
2008 XB Service: Maintenance 1-21
2.15 FENDERS.